ASSIGNMENT – 2

Q1. Explain the principle of ECM process.

Ans 1.
Electrochemical machining (ECM) is a machining process in which electrochemical process is
used to remove materials from the workpiece. In the process, workpiece is taken as anode and
tool is taken as cathode. The two electrodes workpiece and tool is immersed in an electrolyte
(such as NaCl). When the voltage is applied across the two electrodes, the material removal from
the workpiece starts. The workpiece and tool is placed very close to each other without touching.
In ECM the material removal takes place at atomic level so it produces a mirror finish surface.

Working:
ECM working is opposite to the electrochemical or galvanic coating or deposition process.
During electrochemical machining process, the reactions take place at the electrodes i.e. at the
anode (workpiece) and cathode (tool) and within the electrolyte.
We generally use neutral salt solution of sodium chloride (NaCl) as the electrolyte to machine
ferrous alloys. The ionic dissociation of NaCl and water takes place in the electrolyte.
As the potential difference is applied across the electrode, the movement of ions starts in
between the tool and w/p. The positive ions move towards the tool (cathode) and negative ions
move towards the workpiece.
At cathode the hydrogen ions take electrons and gets converted into hydrogen gas.
Within the Electrolyte, the sodium ions combine with Hydroxyl ions and form sodium hydroxide
and ferrous ion combine with Chloride ions and forms ferrous chloride. Also, iron ions combine
with hydroxyl ions and form Iron hydroxide.
In the electrolyte the FeCl2 and Fe (OH)2 produced and gets precipitated in the form of sludge
and settle down. In this way material is removed from the workpiece as sludge.

Q2. How will you differentiate ECM and EDM process? Write the key points.
Ans 2.
Electro-Discharge Machining (EDM) Electro-Chemical Machining (ECM)
EDM is thermal energy based non- ECM is electrical energy based non-
traditional machining process. traditional machining process.
 Material removal takes place by melting Material is removed by controlled electro-
and vaporization (spark erosion). It is one chemical dissolution of work metal (anode).
volume removal process. Material removal takes place in the form of
ions (instead of direct volume removal).

Owing to electric spark, significant heat No heat generation takes place in ECM.
is generated in EDM process. The
localized temperature reaches as high as
10,000°C.
An appropriate dielectric fluid (such as A suitable electrolyte (such as NaCl and
kerosene, paraffin, deionized water) is NaNO3) is applied in ECM to assist flow of
used in EDM to assist spark generation. ions between two electrodes.

EDM process typically requires high ECM process requires moderate voltage
potential difference (50 – 400V) and (<50V) but very high current (>1000A).
moderate current (100 – 200A).

Q3. Explain the necessity of cleaning the work piece after ECM.
Ans 3.
Proper cleaning of the workpiece is essential after ECM to prevent residue from hardening on it.

Q4. Why is the electrolyte circulated at a high velocity?

Ans 4.
High velocity flow over the electrode surface is one of the key factors of ECM. It is necessary to
prevent crowding of hydrogen gas and debris of machining. The electrolyte, which is generally a
concentrated salt solution flows through the inter electrode gap with high velocity to intensify the
mass transfer through the sub layer near anode and to remove the sludge, heat and gas bubbles
generated in the gap.

Q5. Write two dielectric fluids used in EDM and two electrolytes in ECM.
Ans 5.
EDM: Generally, kerosene or deionized water is used as the dielectric medium.
ECM: Common electrolytes used are sodium chloride, sodium nitrate, sodium hydroxide,
sodium fluoride, sodium chlorate, potassium chloride and sulphuric acid.
Q6. Explain the need of a pulse generator in EDM.
Ans 6.
EDM pulse power generator applies voltage pulses between the electrode and workpiece to
generate sparks through the gap. The essential requirement for EDM system is to obtain the
output waveform similar to the ideal EDM waveform. The design is based on transistor type
pulse power generator circuit.

Q7. What is tool wear in EDM process? How does it occur? How will you minimize the tool
wear?
Ans 7.
Electrical Discharge Machining is a one type of an Unconventional Machining Technique. It is
an electrical energy based unconventional machining process. The electrical energy is directly
used to remove or cut the metals. It’s also called as Spark Erosion Machining or Electro Erosion
Machining. The metal is removed by electrical spark discharge between tool (Cathode) and
workpiece (Anode).
The tool and workpiece are submerged in the dielectric medium. The servo feed mechanism is
used to give a constant gap (spark gap) between the tool and workpiece.
When the DC supply is given to the circuit, the voltage across at 250V and high spark is
produced at the spark gap. So that the dielectric breaks down and electrons are emitted from
cathode, the gap is ionized and thousands of sparks/secs occurred at the gap. This high spark
produces high temperature. Due to that high temperature and high pressure the metal is removed
and flushed away by the dielectric fluid.
Lower Material Removal Rate is obtained at low value of peak Current. Lower Material
Removal Rate is obtained at low value of Pulse on Time.

Q8. Explain the basic principle of EDM with its advantages and applications.
Ans 8.
Working Principle:
In Electrical discharge machining; a potential difference is applied across the tool and w/p in
pulse form. The tool and workpiece must be electrically conductive and a small gap is
maintained in between them. The tool and workpiece is immersed in a dielectric medium
(kerosene or deionized water). As the potential difference is applied, electrons from the tool start
to move towards the workpiece. Here the tool is negative and w/p is positive.
The electrons moving from the tool to the w/p collide with the molecules of dielectric medium.
Due to the collision of electrons with the molecule, it gets converted into ions. This increases the
concentration of electrons and ions in the gap between the tool and w/p.
The electron moves towards the w/p and ions towards the tool. An electric current is set up in
between the tool and w/p and called as plasma. As the electrons and ions strikes the w/p and tool,
its kinetic energy changes to heat energy. The temperature of the heat produced is about 10000
degree Celsius.
This heat vaporizes and melts the material from the workpiece. As voltage is break down, the
current stops to flow between the tool and w/p. And the molten material in the w/p is flushed by
circulating dielectric medium leaving behind a crater.
The spark generation is not continuous because constant voltage is not applied across the
electrodes. The voltage is applied in pulse form.
Advantages:
1. It can be used to machine any material that is electrically conductive.
2. It can easily machine thin fragile sections such as webs or fins without deforming the
part.
3. Complex dies sections and molds are produced accurately, faster and at lower price.
4. It is burr-free process.
5. It does not involve contact between the tool and workpiece. So delicate sections and work
material can be machined easily without any distortion.
6. It can machine complex shapes which is not manufactured by the conventional machine
tools.
7. It can produce tapered holes.
Application:
1. It is mostly used by mold making and dies industries.
2. It is used in prototype manufacturing in aerospace, automobile and electronic industries.
3. It is used for coinage die making.
4. It is used to create small holes in variety of application.
5. It is used to disintegrate parts which cannot be disintegrate easily such as broken tools
(studs, bolts drill bit and taps) form the workpiece.

Q9. Why is the EDM process especially suitable for making blanking dies.
Ans 9.
The manufacturing of highly tailored dies and molds call for extreme accuracy. As they feature
demanding design points such as sharp internal corners, narrow slots, deep ribs and other
intricate shapes. There is no other tool that can achieve the high-precision machining required for
the manufacturing of die and mold parts without segmenting the features into simpler shapes.
Moreover, the EDM’s ability to achieve such a fine surface finish, surface integrity and high
precision minimizes or eliminates the need for polishing and other secondary processes. Finally,
dies are usually made out of very hard steel alloys making it necessary for roughing and or
finishing prior to heat treatment dramatically reducing the accuracy of the detail. This typically
translates into custom hand work, spotting and fitment which also makes repair and maintenance
of the tool time consuming and costly.

Q10. What is the use of dielectric in EDM process?

Ans 10.
The EDM's dielectric fluid is designed to be a semiconductor with specific voltage and amperage
characteristics. In EDM work the electrode never actually touches the workpiece, and there is a
small gap—called the spark gap—that must be maintained to make the process stable.
EDM dielectric fluid serves two main purposes: First, it acts as a semiconductor between the
electrode and workpiece to facilitate a stable and controlled spark gap ionization condition.
Second, it also acts as a flushing agent to wash and remove the eroded debris from the spark gap
area.