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MANUFACTURING THROUGH ELECTRO CHEMICAL MACHINING

ABSTRACT:
The machining of complex shaped designs was difficult earlier, but with the advent of the new machining
processes incorporating in it chemical, electrical & mechanical processes manufacturing has redefined
itself. This paper intends to deal with one of the revolutionary process called Electro Chemical Machining
(ECM).

INTRODUCTION:
Electro chemical machining (ECM) is the controlled removal of metal by anodic dissolution in an electrolytic
medium in which the work piece is the anode & the tool is the cathode.
Working: Two electrodes are placed at a distance of about 0.5mm & immersed in an electrolyte, which is a
solution of sodium chloride. When an electrical potential of about 20V is applied between the electrodes,
the ions existing in the electrodes migrate toward the electrodes.
Positively charged ions are attracted towards the cathode & negatively charged towards the anode. This
initiates the flow of current in the electrolyte. The electrolysis process that takes place at the cathode
liberates hydroxyl ions & free hydrogen. The hydroxyl ion combines with the metal ions of anode to form
insoluble metal hydroxides &the material is thus removed from the anode. This process continues and the
tool reproduces its shape in the work piece (anode). The high current densities promote rapid generation
of metal hydroxides and gas bubble in the small spacing between the electrodes. These become a barrier
to the electrolyzing current after a few seconds. To maintain a continuous high density current, these
products have to be removed continuously. This is achieved by circulating the electrolyte at high velocity
through the gap between the electrodes. It is also to be noted that the machining gap size increases.
Therefore to maintain a constant gap the cathode should be advanced towards the anode at the same rate
at which the material is removed.

ELECTROLYTES & ELECTROLYTE SYSTEMS:

The electrolyte has three main functions in ECM:
1. It carries the current between the tool and the work piece.
2. It removes the product of machining from the cutting region.
3. It dissipates heat produced in the operation.
ELECTROLYTE FLOW ARRANGEMENT
Correct electrolyte flow across the tool is essential for proper machining. Attention should be paid to the
tool shape where cavitation of the electrolyte is likely to occur. Tool design must permit a uniform
electrolyte flow in all machining areas. Excessive flows are not desirable as they cause tool erosion.
Basically, two methods of flow are used, namely divergent flow and convergent flow. The convergent flow
method provides a smooth flow of electrolyte. The electrolyte is admitted through a chamber called ‘dam’
to pressurize the area outside the work and the tool. The advantages of the system are:
1. More uniform and predictable side over cut and front machining gap.
2. Improved surface finish.
3. Reduced possibility of arcing.
4. Much cleaner operating conditions.
5. Elimination of undesirable machining due to stray currents.
It is, however, to be noted that cost of tooling with convergent flow is more than that with divergent flow
system.

ECM PROCESS CHARACTERISTICS

Material removal rate:
It depends chiefly on feed rates. The feed rate determines the current passed between the work & the
tool. As the tool approaches the work, the length of the conductive current path decreases & the
magnitude of current increases. This continues until the current is just sufficient to remove the metal at a
rate corresponding to the rate of tool advance. A stable cut is then made with a fixed spacing between the
work and the tool, termed as the equilibrium-machining gap. If the tool feed rate is reduced, the tool
advance will momentarily lag behind, increasing the gap and thus resulting in a reduction of current. This
happens until a stable gap is once again established.
Accuracy:
Under ideal conditions & with properly designed tooling, ECM is capable of holding tolerance of the order
of .02 mm & less. Repeatability of the ECM process is also very good. This is largely due to the fact that
the tool wear is virtually non-existent on a good machine, tolerance can be maintained on a production
basis in the region of .02-.04 mm. As a general rule, the more complex the shape of the work, the more
difficult is to hold tight tolerances, and the greater is the attention required for developing a proper tooling
and electrode shape.
Surface Finish:
ECM under certain conditions can produce surface finishes of the order of 0.4µ m. This can be obtained by
the frontal cut or the rotation of the tool or the work. The important variables affecting the surface finish
are feed rate, gap dimension, electrolyte composition, viscosity, temperature & flow. Any defect on the
tool will cause machining defects on the surface of the work.
The operating parameters which are within the control of the operator and which influence ECM process
capabilities can be described as follows:

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1. Feed Rate:
A high feed rate results in higher metal removal rate. It decreases the equilibrium machining gap
resulting in improvement of surface finish and tolerance control.

2. Voltage:
Low voltage decreases the equilibrium-machining gap and results in better surface finish and
tolerance control.

3. Electrolytic Concentration:
Low concentration decreases the equilibrium machining gap and thus a better surface finish and
tolerance control is achieved.

4. Electrolytic Temperature:
Low temperature is conducive for better surface finish and tolerances.
It should be noted that the metal removal rate is comparatively lower with low voltage, low electrolytic
concentration and low temperature.

ECM TOOLING
Tooling design is the key to successful application of ECM. There are two aspects of the design of ECM
tooling. The first is the determination of tool size together appropriate machining conditions necessary to
produce the required shape. The second part of the tool design is concerned with making the tool of
appropriate material, foxing it on the machine connecting it to the power supply, arranging an adequate
supply of electrolyte between the tool and work piece and insulating a part of the tool to prevent over
cutting and generating a taper.

APPLICATION OF ECM TECHNIQUE

ECM is to be applied only in specialized areas where conventional machining is not feasible. One of the
main applications of ECM is in the aerospace industry to machine difficult-to-machine materials and
complex shaped parts.
1. ELECTROCHEMICAL TURNING
The tool is made as wide as possible to cover the intended area. Holes are provided in the end of the tool
to supply the electrolyte. The tool is fed into the work in the same way as in conventional machining. The
electrical and other parameters are the same as in ECM.
2. DRILLING AND TREPANNING
It is a process of drilling performed in ECM. The tool is a tube with insulated sides and the electrolyte is
fed down the center of the tube to the working gap. It is suitable for producing deep, small-diameter
holes in tough materials. Electrochemical drilling is extensively used for drilling the cooling holes in gas
turbine blades. The chief advantage of this process is that the holes are burr-free and can be made in thin
work pieces.
CONCLUSION:
The basic advantages of ECM are found to be:
1. The tool does not wear. Once the tool is developed it can be used indefinitely
2. There are no thermal or mechanical stresses on the work piece.
3. Faster stock removal & better surface finish can be obtained.
4. The hardness of the work piece is not a factor.
5. Any shape that can be produced in a tool can be reproduced in the work piece.
However the cons of the machine are:
1. The cost of the equipment is very high.
2. Rigid fixturing is required to withstand the high electrolyte flow rates.
3. The tool is more difficult to make since it must be insulated to maintain correct conductive paths
to the work piece.
REFERENCE:
Production Technology by HMT
Processes and Materials of Manufacture by R.A. LINDBERG
Production Technology by O.P. KHANNA & LAL
www.ccm.com
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