Electrochemical Turning

The electrochemical machining process can be used to perform tasks that

would traditionally be accomplished by a single-point cutting tool on a
lath.electrochemical turning (ECT) is used to remove material from the
internal surface (ID), external surface (OD), or face of rotating
electrically conductive work-pieces.

Figure 1 depicts the ECT process performing an OD turning operation. If

the particular ECT machine has sufficient power, tools are constructed to
be as wide as the final shape being generated. Using the technique,
contoured shapes can be plunged into the work-piece in a single pass.
During operation, the ECT tool never contacts the work-piece; a gap is
constantly maintained between the two. The gap is continuously flooded
with electrolyte, which is delivered through holes in the tip of the tool.
The equipment used for ECT resembles a conventional lathe except for
the additional enclosures to contain the corrosive electrolyte and the
addition of the power supply. Because ECT is rather limited in its use,
equipment is made by special order. Depending upon the application,
machines can be configured as either a vertical or horizontal lathe. Power
supplies have attached to ECT machines with ratings as high as 20,000
amp.

Very thin work-piece sections can be turned of faced with ECT because
ther is no physical contact between the ECT tool and work-piece. Disks
as thin as 0.12 mm (0.005 in.) can be turned without distortion because
there are no tool forces. In addition, material hardness has no influence
on removal rates and ther is no tool wear to decrease quality or
productivity.
ECT is a special application of ECM. The principles of ECM are applied
in the process to electrolytically machine rotating work-piece. Peripheral
cuts and face cuts are accomplished as illustrated in figure 2.
ECT is distinguished from a related process, electromechanical
machining (EMM), in the ECT employs a noncontacing tool and all metal
removal is accomplished via elecrolytic action. In contrast, EMM is a
traditional machining process in every way except that electrolyte is
flooded over the work-piece surface to soften it prior to mechanical metal
removal by traditional tools.

Application
Large disk forgings are machined using ECT. In some cases, full-
face electrodes are plunged into a rotating disk. Bearing races have
been finished, with close tolerances and with surface roughness
held to less than 5 μ in.(0.13 μ m)Ra . Another application, AISI
316 stainless steel work-piece (2.5" ,6.35 mm diam) are
electrochemical turned, using an electrolyte of NaCl and NaNo3
(2:3), to a surface finish of less than 10 μ in.(0.25 μ m)Ra with out-
of-roundness of less than 0.0002" (0.005 mm) TIR.
Operating parameters
Material removal rates and tolerances are similar to those achieved
in ECM. Tolerance holding capability usually is between ±0.0015-
0.003" (0.038-0.08 mm). Under unusual conditions, tolerances can
be held to ±0.001" (0.03mm); and in rate cases, tolerances can be
held to ±0.0005" (0.013 mm).
Surface finish under normal conditions can be held to about 16-63
μ in. (0.4-1.6 μ m) Ra . with particular care, surface roughness can
be held to as low as 8μ in.(0.2μ m)Ra : under special conditions,
surface roughness can be controlled to 4μ in.(0.1μ m)Ra.
Equipment
Peripheral and face ECT machines are available on special order.
Capacities are provided up to about 20,000 A. one horizontal
electrochemical lathe is equipped with 5000 A power supply. The
lathe is used to hold 0.0003" (0.008mm) tolerances.