Electrochemical Machining ECM

R.K.
RANA [LECTURER]
M.Tech (P), B.Tech, LMIEI
YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM
Electro Electro-Chemical Grinding

Electro-chemical chemical grinding (ECG) is a variant process of the basic ECM. It is a burr free and stress free material removal process, wherein material removal of the electrically conductive material takes place through mechanical (grinding) process and electroelectro chemical process. The abrasive laden grinding wheel is negatively charged and the workpiece is positively charged. They are separated by an electrolyte fluid. The fine chips of the material that is removed from the workpiece (debris) stays in the electrolyte fluid, which is further filtered out. Electrochemical grinding and electrochemical machining are similar processes with a difference that a wheel substitutes the tool used in ECM. The wheel shape is similar to the desired work shape. The schematic of the electrochemical grinding is shown in fig. 1 Process of Grinding in ECM The main feature of electrochemical grinding (ECG) process is the use of a metallic grinding wheel which is embedded with insulating abrasive particles such as diamond, set in the conducting material. Copper, brass, and nickel are the most commonly used materials while aluminum oxide is a typical abrasive used while grinding steels. The commutator is an electrolytic spindle having carbon brushes and holds the grinding wheel. It receives a negative charge from the DC power supply and the workpiece is given a positive charge. In ECG process, the grinding wheel slightly touches the workpiece. Electrolyte is supplied on on-to the grinding wheel near the workpiece piece such that the wheel carries it through the cutting process thereby resulting in an electro-chemical electro action. A nozzle similar to the one which carries coolant in a conventional grinding process is provided, which enables the flow of the electrolytic fluid luid to the work-tool work contact area. The electrolyte along with wheel works simultaneously in the process of cutting. The electro-chemical chemical cells thus formed further oxidize the surface of the workpiece. The wheel carries away the formed oxides thereby exposing ing the fresh metal layers beneath the workpiece. In this process of ECG, the major material removal activity takes place by the electrolytic action (around 90%). Rest of the metal removal takes place due to the grinding action along with abrasives used (embedded embedded in the wheel). This mechanical action contributes to around 10% due to abrasive action of the conducting grinding wheel. The pressure applied on the grinding wheel is also much lesser than the conventional grinding process. Thus the very basic nec necessity of frequent wheel dressings and truing as in the case of conventional process is also eliminated. The schematic of the electrochemical grinding process is shown in Fig. 1
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R.K. RANA [LECTURER]

Figure 1: Schematic of ECM Grinding Process Process Characteristics: The life of grinding wheel in ECG process is very high as around 90% of the metal is removed by electrolysis action and only 10% is due to the abrasive action of the grinding wheel. The ECG process is capable of producing very smooth and burr free edges unlike those formed during the conventional grinding process (mechanical). The heat produced in the ECG process is much less, leading to lesser distortion of the workpiece. The major material removal activity in ECG process occurs by the dissolving action through h the chemical process. There is very little tool and workpiece contact and this is ideally suited for grinding of the following categories: o Fragile work-pieces pieces which otherwise are very difficult to grind by the conventional process o The parts that cannot withstand thermal damages and o The parts designed for stress and burr free applications. Applications The applications of ECG process include the following: In production of tungsten carbide cutting tools. In burr-free free sharpening of hypodermic needles. In grinding of super-alloy alloy turbine blades. In form grinding of aerospace honeycomb metals. In removal of fatigue cracks from steel structures that have been used for underwater applications.
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The ECG process can be applied to the following common methods of grinding. 1) Face Wheel Grinding. 2) Cone Wheel grinding. 3) Peripheral or Surface grinding. 4) Form Wheel or Square grinding. The Subsystems of Electro-Chemical Chemical Machining Power supply. Electrolyte circulation system. Control system. The Machine. In the ECM setup, as the gap between tool and workpiece is small, a low and constant voltage of around 10 V is applied across the electric circuit. The current density is however high. The electrolyte chosen is such that the shape of cathode is not changed during electrolysis. To remove the products of machining and to reduce the undesirable effects which may arise with the gases generated at the cathode and electrical heating, the electrolyte is pumped at a rate of 2 to 30 m/s, through the gap between the electrod electrodes. The electrolyte system consists of the electrolyte storage tank, fairly strong pump, filter, sludge removal system and treatment units. Control of ECM process refers to a predetermined adjustment of process parameters. Thus control of the process para parameters meters in ECM is very vital as the rate of material removal, surface finish and accuracy of machining depends upon the accuracy of the control parameters. The control parameters include voltage, type of electrolyte, inlet and outlet pressure of electrolyte electrolyte, , viscosity of electrolyte and the temperature of electrolyte. The current of the electrical system in ECM under operating condition is dependent on the above parameters and the feed rate of the tool. The general requirements of the tool material in ECM a are re mentioned below: The material used in tool tool-making making needs to be a good conductor of electricity. The tool should be rigid enough to take up load and the fluid pressure. The tool should be chemically inert with the electrolyte. The tool material should be easily formable and machinable to the desired shape. Copper, Brass, Titanium, Copper Copper-Tungsten Tungsten and Stainless steels are most commonly used electrode materials when the electrolyte is made of sodium or potassium. www.CrazyProf.in www.RamakantRana.blogspot.com

The other materials which can be used as tool materials are aluminium, graphite, bronze, platinum, and tungsten carbide. The hole or cavity produced through ECM is an exact replica of the tool shape. Thus the tool shape and its accuracy have a direct effect on the work piece accuracy. s Parameters The ECM Process The ECM process parameters can be subdivided into the following sub sub-categories. categories. The Ishikawa cause and effect diagram of ECM process parameters is shown in Fig. 3.15.1. Power Supply: Its Type, Voltage, Current and Current density. Electrolyte: Its type, Temperature, Flow rate, Pressure and Dilution. Machine setting parameters: Working gap, Overcut and Feed rate. Electrode material: Type of the material used.
Electrochemical machining is a technology used for machining metals. It is based on electrolysis through which the product is processed without the tool tool-workpiece workpiece contact or any thermal influence. The metallic workpiece is dissolved (Machined) locally through electricity (Electro) and chemistry (Chemical) until it reaches t the he desired end shape. As discussed earlier, the material removal process in ECM occurs through atomic level dissolution by the electrochemical action. The material removal rate (or machining rate) is thus not dependent on the mechanical or physical propert properties ies of the work material. It
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only depends on the atomic weight and valency of the work material and the important condition is that the material should be electrically conductive. The most important feature in ECM is that, it can machine any electrically c conductive onductive work material irrespective of its hardness, strength or even thermal properties. The various uses of ECM are: Sinking operations o Die-Sinking o Deburring operations o Drilling operations o Grinding operations and o Micro-machining machining operations The various uses of ECM have been schematically shown in the following figures, Fig. 3.15.2, 3.15.3 and 3.15.4
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Electrochemical Machining (ECM)

Electrochemical machining is a method of removing metal by an electrochemical process. It is a non-traditional traditional machining process belonging to the electrochemical category. It is used for machining extremely hard materials or materials that are difficult to machine using conventional methods. Its use is limited to electrically conductive materials. The process has the capabilities ities of machining or cutting the intricate contours or cavities in hard steel such as titanium, Hastelloy, Kovar, Inconel, and Carbide. External as well as internal geometries can be machined with an electrochemical machine. ECM is characterized as the opposite of electrochemical or galvanic coating or deposition process. It is sometimes referred to as reverse electroplating since it removes material instead of depositing it. In the year 1833, Faraday established the laws of electrolysis (electroplating). . The mechanism in ECM process is similar to electrical discharge machining (EDM) concept concept-wise, wise, wherein a high current is passed between the tool (cathode) and the workpiece (anode), through a conductive fluid (electrolyte). However, in ECM there is no to tool wear. In ECM, the metal removal takes place by electrochemical dissolution of an anodically polarized workpiece. By using the ECM process, very hard metals can be easily shaped electrolytically and being a chemical process, the rate of machining does no not t depend on the hardness of workpiece. Soft materials can be readily used as tool materials on harder work-pieces pieces in ECM process since the tool doesnt wear unlike in the case of conventional machining methods. ECM Fundamentals ing the most fundamental activity in ECM, its characteristics The electrolysis process being are to be well understood before proceeding further into its other process details. Electrolysis, as the name suggests is a chemical phenomenon that occurs between two conductors dipped in a suitable itable solution when electric current is passed between them. Example two copper wires, dipped in a copper sulphate solution are connected to a source of direct current as shown in Fig. 3.14.1. This solution of copper sulphate is termed as the electrolyte and it has electrical conducting property. The entire system of electrolyte and electrodes is called as the electrolytic cell. As per the polarity, the chemical reactions occurring at the anode and cathode are called as anodic or cathodic reactions respectively.
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Electrolytes are different from the metallic conductors that conduct electricity. In electrolytes, the current is carried by atoms or group of atoms and not by the electrons. The atoms have either lost or gained electrons, thereby acquiring either positive or negative charges and such atoms are called ions. The ions that carry positive charges are attracted by the cathode and they move through the electrolyte in the direction of the positive current and are referred to as the cat cat-ions. The negatively charged ions get attracted to the positive electrode i.e. anode and they are referred to as the anions. Due to the potential difference applied, the movement of ions is accompanied by the flow of electrons, in the opposite sense to the positiv positive e current in the electrolyte, outside the cell, as shown schematically in Fig. 3.14.2
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In the electroplating process, which is a very popular a application pplication of electrolysis, the metal coatings are deposited on the surface of a cathodically polarized metal. An example of the anodic dissolution operation is electro electro-polishing. polishing. In this polishing process, the workpiece which has irregularities is made as the anode in the electrolytic cell. The workpiece gets polished and irregularities on its surface are dissolve dissolved preferentially so that after the process, the item gets shining effect and becomes flat. The ECM and electro-polishing polishing process are similar, such that both are anodic dissolution processes. The rate of metal removal obtained in the electro electro-polishing polishing process proce is considerably less than that required in the metal removal processes. Some observations relevant to ECM are: At the anode, the metal dissolves electrochemically and its rate of dissolution depends upon number of factors such as the ionic charge, atomic weight, the current and the time of current passage. The rate of dissolution is not influenced by the hardness of the workpiece material or any other metal characteristics. At the cathode, only the hydrogen gas is evolved. The electrode shape remains unaltered during the electrolysis process. This is the most relevant feature of ECM being used as a metal shaping process. Mechanism of Material Removal in ECM The working principle of ECM is schematically shown in Fig. 3.14.3 (a and b), the workpiece iece and tool are the anode and cathode respectively. In the electrolytic cell a constant potential difference, usually of about 10 V is applied across them. A suitable electrolyte, for example an aqueous sodium chloride (table salt) solution is commonly chosen. In-order order to remove the products of machining, the electrolyte is pumped through the gap between the two electrodes. The rate at which metal is then removed from the anode is approximately in inverse proportion to the distance between the electrodes. As the machining proceeds there is a simultaneous movement of the cathode towards the anode. The width of the gap along the electrode length will gradually tend towards a steady steady-state state value. Under such conditions, a shape which is roughly complementary to that of the cathode will be reproduced on the anode. The schematic of electrochemical machine is shown in Fig. 3.14.4
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Advantages of ECM The major advantages of the ECM process are: No heat affected zone is formed. Harder metals than the tool can be machined. The hardness of material does not affect the metal removal rate. Complex shapes can be machined on hard metals, No tool wear occurs. Burr-free free products are obtained in this process. There is no tool to workpiece contact. There is no cutting forces, therefore clamping is not required except for controlled motion of the work piece. The products obtained are free from physical and thermal strains. Depending on the materials, high surface quality level is attainable (Ra < 0.02 Am) imensional accuracies are attainable High dimensional Limitations of ECM The cost of tooling is high. Energy consumption is high: Power consumption is more as the ECM processes operates at high current and relatively low voltages (5 (5-15V). The saline electrolyte poses a ri risk sk of corrosion to the tool, workpiece and the equipment. Since special electrodes need to be developed for each product, higher production numbers are required for economic viability. Depending on the complexity of the material, the optimum product number numbers s are decided. The electrode design is complex and has high initial cost but however it has a long life. Sharp corners or flat bottoms are not suitable through the ECM process, as there is a tendency of the electrolyte to erode away the sharp profiles.
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Electrochemical Machining ECM

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R.K.

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

Electro Electro-Chemical Grinding

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM

R.K. RANA [LECTURER]

YouTube.com/RamakantRana RamakantRana ELECTRO-CHEMICAL CHEMICAL GRINDING ECM