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ELECTRO CHEMICAL MACHINING
[ECM]
SUBJECT : MANUFACTURING ENGINEERING - 3
PREPARED BY : JAYKUMAR R. SONAR
ENROLL. NO : 149740319047
GUIDED BY :
MR. D . T . PATEL
OUTLINE
 Definition Of Topic
 Aims Of Usage
 History
 Basic Working Principle
 Tools Of System
 Advantages And Disadvantages
 Applications
 Economics
 Products
 WHAT IS ECM ?
 Electrochemical Machining (ECM) Is a Method
of Removing Metal Particles by an Electro-
Chemical Process Instead of Standard Machining
Methods .
 It Gives a New Perspective To Machining
Process And Being An Initiator Of New
Technologies .
 AIM OF USAGE
 To Process Complex Materials Which Standard
Machining Methods Are Insufficient .
 Also For Processing Extremely Hard And Brittle
Materials With High Sensitivity .
 HISTORY
 The First Introduction Of ECM Was In 1929
By Gusseff , Its Industrial Applications Have
Been Extended To Electro-Chemical Drilling ,
Electro-chemical Deburring , Electro-Chemical
Grinding And Electro-Chemical Polishing .
 The Techniques Was Applied In Several Ways .
And As A Machining Technique In The 60’s &
70’s.
 WORKING PRINCIPLE
 As The Tool Approaches
The Work Piece It Erodes
The Negative Shape Of It.
Thus Complex Shapes
Are Made From Soft
Copper Metal And Used
To Produce Negative
Duplicates Of It.
• Anode Reaction
Fe  Fe++ + 2e
• Cathode Reaction
2H2O + 2e  H2 + 2OH-
ELECTRO-CHEMICAL MACHINING
ILLUSTRATION SCHEMATIC DIAGRAM
 MADE BY ELECTROCHEMICAL
MACHINING ( ECM )
 In ECM , Cathode parts Must Design
Specially To Machining Work piece.
 TOOL OF ECM SYSTEM
 The Power Supply
 The Electrolyte Circulation System
 The Control System
 The Machine
 POWER SUPPLY
o Electrical Energy Is Using To Work ECM,
For This Power Lots Of Specialties Includes.
o Electric Current Density Must Be High.
o The Space Between Electrode And Work piece
Must Be Very Short For Higher Accuracy.
 ELECTROLYTE CIRCULATION SYSTEM
 The Entering Pressure Must Be Between 0.15
To 3 MPA .
o The Electrolyte System Must Include a Strong
Pump.
 The Electrolyte Is Stored In a Tank .
o System Also Includes A Filter , Sludge Removal
System , And Treatment Units.
 CONTROL SYSTEM
 Control Parameters Includes :
-> Voltage.
-> Inlet and Outlet Pressure Of Electrolyte.
-> Temperature Of Electrolyte.
 The Current Is Dependent On The Parameters
Given Above And The Feed Rate.
 THE MACHINE
 The Machine Is a Major Subsystem Of The
ECM .
 It Includes The Table , Frame , Work Enclosure
( prevents the electrolyte from Spilling ) , The
Work Head ( Where the tool Is Mounted ) .
 The Tools ( electrodes ) are Also Part Of The
Machine System.
 ADVANTAGES OF ECM
 No mechanical force.
 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.
 No material corrosion.
 Provides smooth surfaces.
 More sensitive and repeatable.
 DISADVANTAGES OF ECM
 Solution usage In :
• Pump , tank , pipe , filter .
 More expensive than conventional machining.
 Need more area for installation.
 Electrolytes may destroy the equipment.
 Not environmentally friendly (sludge and other waste)
 The effect of the toxic gases and aerosols produced in the
course of ECM.
 The risk of an electric shock.
 The danger of a burn in the case of a short circuit
between the positive and negative leads.
 Mechanical factors.
 Material has to be electrically conductive.
 APPLICATION OF ECM
 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.
 APPLICATIONS IN INDUSTRIES
 Applications are valid for highly sensitive working
areas like; electronic, air and space industries.
 It has also contains many benefits that in industries
like Telecommunication , Automotive and Defense
industries.
 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.
 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.
 Some of these mechanical characteristics achieved
by ECM are: Stress free grooves.
*Any conductive metal can be machined.
*Repeatable accuracy of 0.0005”.
*High surface finish.
*Fast cycle time.
THANK YOU

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Electro chemical machining

  • 1. ELECTRO CHEMICAL MACHINING [ECM] SUBJECT : MANUFACTURING ENGINEERING - 3 PREPARED BY : JAYKUMAR R. SONAR ENROLL. NO : 149740319047 GUIDED BY : MR. D . T . PATEL
  • 2. OUTLINE  Definition Of Topic  Aims Of Usage  History  Basic Working Principle  Tools Of System  Advantages And Disadvantages  Applications  Economics  Products
  • 3.  WHAT IS ECM ?  Electrochemical Machining (ECM) Is a Method of Removing Metal Particles by an Electro- Chemical Process Instead of Standard Machining Methods .  It Gives a New Perspective To Machining Process And Being An Initiator Of New Technologies .
  • 4.  AIM OF USAGE  To Process Complex Materials Which Standard Machining Methods Are Insufficient .  Also For Processing Extremely Hard And Brittle Materials With High Sensitivity .
  • 5.  HISTORY  The First Introduction Of ECM Was In 1929 By Gusseff , Its Industrial Applications Have Been Extended To Electro-Chemical Drilling , Electro-chemical Deburring , Electro-Chemical Grinding And Electro-Chemical Polishing .  The Techniques Was Applied In Several Ways . And As A Machining Technique In The 60’s & 70’s.
  • 6.  WORKING PRINCIPLE  As The Tool Approaches The Work Piece It Erodes The Negative Shape Of It. Thus Complex Shapes Are Made From Soft Copper Metal And Used To Produce Negative Duplicates Of It. • Anode Reaction Fe  Fe++ + 2e • Cathode Reaction 2H2O + 2e  H2 + 2OH-
  • 8.  MADE BY ELECTROCHEMICAL MACHINING ( ECM )
  • 9.  In ECM , Cathode parts Must Design Specially To Machining Work piece.
  • 10.  TOOL OF ECM SYSTEM  The Power Supply  The Electrolyte Circulation System  The Control System  The Machine
  • 11.  POWER SUPPLY o Electrical Energy Is Using To Work ECM, For This Power Lots Of Specialties Includes. o Electric Current Density Must Be High. o The Space Between Electrode And Work piece Must Be Very Short For Higher Accuracy.
  • 12.  ELECTROLYTE CIRCULATION SYSTEM  The Entering Pressure Must Be Between 0.15 To 3 MPA . o The Electrolyte System Must Include a Strong Pump.  The Electrolyte Is Stored In a Tank . o System Also Includes A Filter , Sludge Removal System , And Treatment Units.
  • 13.  CONTROL SYSTEM  Control Parameters Includes : -> Voltage. -> Inlet and Outlet Pressure Of Electrolyte. -> Temperature Of Electrolyte.  The Current Is Dependent On The Parameters Given Above And The Feed Rate.
  • 14.  THE MACHINE  The Machine Is a Major Subsystem Of The ECM .  It Includes The Table , Frame , Work Enclosure ( prevents the electrolyte from Spilling ) , The Work Head ( Where the tool Is Mounted ) .  The Tools ( electrodes ) are Also Part Of The Machine System.
  • 15.  ADVANTAGES OF ECM  No mechanical force.  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.  No material corrosion.  Provides smooth surfaces.  More sensitive and repeatable.
  • 16.  DISADVANTAGES OF ECM  Solution usage In : • Pump , tank , pipe , filter .  More expensive than conventional machining.  Need more area for installation.  Electrolytes may destroy the equipment.  Not environmentally friendly (sludge and other waste)  The effect of the toxic gases and aerosols produced in the course of ECM.  The risk of an electric shock.  The danger of a burn in the case of a short circuit between the positive and negative leads.  Mechanical factors.  Material has to be electrically conductive.
  • 17.  APPLICATION OF ECM  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.
  • 18.  APPLICATIONS IN INDUSTRIES  Applications are valid for highly sensitive working areas like; electronic, air and space industries.  It has also contains many benefits that in industries like Telecommunication , Automotive and Defense industries.
  • 19.  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.
  • 20.  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.  Some of these mechanical characteristics achieved by ECM are: Stress free grooves. *Any conductive metal can be machined. *Repeatable accuracy of 0.0005”. *High surface finish. *Fast cycle time.