ECM is opposite of electrochemical or galvanic

coating or deposition process.

ECM can be thought of a controlled anodic
dissolution at atomic level of the work piece.
It is electrically conductive by a shaped tool due to
flow of high current at relatively low potential
difference. An electrolyte, which is quite often
water based neutral salt solution is used as a
medium.

ECM is often characterized as reverse

electroplating.
This process is similar in concept to electrical
discharge machining in that a high current is
passed between an electrode and the part,
through an electrolyte.
The material removal process having a
negatively charged electrode (cathode), a
conductive fluid (electrolyte) and a conductive
work piece (anode);

Schematically shows the basic principle of ECM

During ECM, there will be reactions occurring at the

electrodes i.e. at the anode or work piece and at
the cathode or the tool along with within the
electrolyte.
As the potential difference is applied between the
work piece (anode) and the tool (cathode), the
positive ions move towards the tool and negative
ions move towards the workpiece.
Thus the hydrogen ions will take away electrons
from the cathode (tool) and from hydrogen gas as:
2H+ + 2e- = H2 at cathode

Similarly, the iron atoms will come out of

the anode (work piece) as:
Fe = Fe+ + + 2eWithin the electrolyte iron ions would
combine with chloride ions to form iron
chloride and similarly sodium ions would
combine with hydroxyl ions to form sodium
hydroxide
Na+ + OH- = NaOH

Schematic representation of electro-chemical reactions

Schematic diagram of an electrochemical drilling unit

No tool wear as non contact working mode

avoiding problems such as vibration and
breakage.
High material removal rate.
Ability to machine a wide variety of materials
without affecting microstructure or surface
properties.
No heat generated during machining.
Cutting, drilling, deburring and shaping
possible.
Environmentally acceptable.

Difficulty in learning to use the process

Heavy initial investment
Difficulty in designing a proper tooling
system

Process Parameters