UNIT-3 ELECTR0-CHEMICAL PROCESSES

Electro-chemical Machining
Latest and potentially available method Michael faraday Electroplating ECM Reverse of Electroplating

Chemistry of Electroplating
Metal to be plated by metal negative charge- cathode Metal used plate positive Charge Anode Put in the same solution Electrons flow from + to where the metal to be plated is being reduced and the metal being used in the process is being oxidized. The positive ions from the salt solution and the metal being used to plate "stick" onto the object being plated since it has a negative charge. The thickness of the metal plating depends on how long you leave it in the solution, and the flow of electrons.

 ECM Reverse of Electroplating ECM uses a shaped tool or Electrode Tool Cathode Work piece Anode Electrolyte is pumped Chemical properties of the electrolytes Constituents go into the electrolyte By proper design the cavity or hole which is exactly produced reproduces the tool shape.

 Cathode tool (Mirror Image) Anode Work piece Source of DC Power Electrolyte Servo motor Pump Filter for incoming Electrolyte Reservoir for electrolyte

 Shaped tool is connected to negative terminal (cathode) Tool should be made up of materials have enough thermal and electrical conductivity, high Chemical resistance to electrolyte. Stainless steel, titanium, Brass, copper, Reinforced plastics. Shaping the tool is not a problem, Easy to machine Cold forging, electroforming Favorable methods.

 No restriction except to be a good conductor of electricity Chemical characteristics of the work material affect MRR. MRR atomic weight and 1/ to the valency of the work material. Fixtures should be of insulating material. Epoxy resin 0r glass fibres For cheapest purpose Perspex , PVC

 Low voltages 2 to 20v Rare time 30v Current 800 amp/cm2 three phase 440v, AC power supply converted by a step down transformer, Rectifier Protective circuits is given Mishandling, Incorrect fitting.

Electrolyte

completing the electric circuit between the tool and the work piece Allowing desirable machining reactions to occur Carrying away heat generated during the chemical reaction Carrying away products of reaction from the zone of machining

Essentials properties and selection

High electrical conductivity Low viscocity and high specific heat Chemical stability Resistance to formation of passivating film on the work surface Non-corrosive and non-toxic in nature Inexpensive and readily available

Commonly used electrolyte

Most application-sodium chloride in water is used Corrosive is a problem Sodium nitrate solution less corrosive in nature Potassium nitrate, sodium chromate, sodium hydroxide, sodium fluoride and potassium chloride. Mixture of two or more is efficient

Concentration of the electrolyte

Low resistance to flow of current But salt crystallize at higher concentration and clog the machine area Dilution is used in certain case

Working life of the electrolyte

Composition of the electrolyte changes during use Main changes are Loss of hydrogen Reduces the electrical conductivity of the electrolyte Loss of water due to evaporation Precipitate formation Salt absorption by the precipitate

Temperature and pressure

Difference in temperature is an important factor Kubeth & Heitmann recorded 45C Decreases the specific resistance of the electrolyte Precautions taken to overheating of the electrolyte An increase in temperature speed up the electrode reactions, reduces the over voltages required Voltage required is reduces with increase in temperature

 In order to obtain good results Remove the contaminated electrolyte from the working Gap Minimize polarization. Limit the rise in temperature of the electrolyte.

Working of ECM
Is a method of removing metal particles by an electrochemical process instead of standard machining methods. First introduction of ECM in 1929 by Gusseff, its industrial applications

 The workpiece is made anode of the setup and material is removed by anodic dissolution. Tool is made cathode and kept in close proximity to the workpiece and current is passed through the circuit. Both electrodes are immersed into the electrolyte solution. This works on the basis of Faradays law of electrolysis. The cavity machined is the mirror image of the tool. MRR in this process can easily be calculated according to Faradays law.

Mechanism of Electrolysis

 First Law The quantity of a substance produced by electrolysis is proportional to the quantity of electricity used. Second Law For a given quantity of electricity the quantity of substance produced is proportional to its weight.

Advantages
There is no cutting forces therefore clamping is not required except for controlled motion of the work piece. There is no heat affected zone. Very accurate. Relatively fast Can machine harder metals than the tool.
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Disadvantages
More expensive than conventional machining. Need more area for installation. Electrolytes may destroy the equipment. Not environmentally friendly (sludge and other waste) High energy consumption. Material has to be electrically conductive.
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Applications
The most common application of ECM is high accuracy duplication. Because there is no tool wear, it can be used repeatedly with a high degree of accuracy. It is also used to make cavities and holes in various products. It is commonly used on thin walled, easily deformable and brittle material because they would probably develop cracks with conventional machining.
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Economics
The process is economical when a large number of complex identical products need to be made (at least 50 units) Several tools could be connected to a cassette to make many cavities simultaneously. (i.e. cylinder cavities in engines) Large cavities are more economical on ECM and can be processed in 1/10 the time of EDM.
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Products
The two most common products of ECM are turbine/compressor blades and rifle barrels. Each of those parts require machining of extremely hard metals with certain mechanical specifications that would be really difficult to perform on conventional machines. Some of these mechanical characteristics achieved by ECM are:

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Stress free grooves. Any groove geometry. Any conductive metal can be machined. Repeatable accuracy of 0.0005. High surface finish. Fast cycle time.
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Safety Considerations
Several sensors are used to control short circuit, turbulence, passivation, contact and overcurrent sensors. In case of contact, immense heat would be generated melting the tool, evaporating the electrolyte and cause a fire. The worker must be insulated to prevent electrocution. The tool and the work piece must be grounded before any handling is performed. Hydrogen gas emitted is very flammable, so it should be disposed of properly and fire precautions should be taken. The waste material is very dangerous and environmentally unfriendly (metal sludge) so it must be recycle or disposed of properly. Electrolyte is highly pressurized and worker must check for minor cracks in piping before28 operating. 13/05/2002 AUC - MENG