Electrochemical Machining (ECM)

RamaKant Rana
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Electro
Electro-chemical grinding (ECG) is a variant process of the basic ECM. It is a
stress free material removal process, wherein material removal of
conductive material takes place through mechanical
chemical process. The abrasive laden grinding wheel is
workpiece is positively charged. They are separated by
chips of the material that is removed from the
electrolyte fluid, which is further filtered out.
Electrochemical grinding and electrochemical machining are similar processes
difference that a wheel substitutes the tool used in ECM. The wheel shape
the desired work shape. The schematic of the electrochemical

Process of Grinding in ECM
The main feature of electrochemical grinding (ECG) process is the use of a
grinding wheel which is embedded with insulating abrasive particles
set in the conducting material. Copper, brass, and nickel are the most
materials while aluminum oxide is a typical abrasive used while

The commutator is an electrolytic spindle having carbon brushes and holds the
wheel. It receives a negative charge from the DC power supply and the
given a positive charge. In ECG process, the grinding wheel slightly
workpiece. Electrolyte is supplied on
the wheel carries it through the cutting process thereby
action. A nozzle similar to the one which carries
process is provided, which enables the flow of
contact area. The electrolyte along with
cutting. The electro-chemical cells
workpiece. The wheel carries away
layers beneath the workpiece.

In this process of ECG, the major material removal activity takes place by the
action (around 90%). Rest of the metal removal takes place
along with abrasives used (embedded in the wheel). This
to around 10% due to abrasive action of the
applied on the grinding wheel is also
process. Thus the very basic necessity
case of conventional process is
The schematic of the electrochemical grinding process is shown in Fig. 1

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ELECTRO-CHEMICAL GRINDING
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Electro-Chemical Grinding

chemical grinding (ECG) is a variant process of the basic ECM. It is a
stress free material removal process, wherein material removal of the electrically
conductive material takes place through mechanical (grinding) process and electro
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
difference that a wheel substitutes the tool used in ECM. The wheel shape
work shape. The schematic of the electrochemical grinding is shown in fig. 1

The main feature of electrochemical grinding (ECG) process is the use of a
grinding wheel which is embedded with insulating abrasive particles such
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.
is an electrolytic spindle having carbon brushes and holds the
wheel. It receives a negative charge from the DC power supply and the
given a positive charge. In ECG process, the grinding wheel slightly
yte is supplied on-to the grinding wheel near the workpiece such that
the wheel carries it through the cutting process thereby resulting in an electro
action. A nozzle similar to the one which carries coolant in a conventional grinding
provided, which enables the flow of the electrolytic fluid to the work
contact area. The electrolyte along with wheel works simultaneously in the process of
chemical cells thus formed further oxidize the surface of the
The wheel carries away the formed oxides thereby exposing the fresh metal
layers beneath the workpiece.
In this process of ECG, the major material removal activity takes place by the
action (around 90%). Rest of the metal removal takes place due to the grinding action
along with abrasives used (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 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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burr free and
the electrically
process and electro-
negatively charged and the
an electrolyte fluid. The fine
(debris) stays in the
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
grinding is shown in fig. 1
The main feature of electrochemical grinding (ECG) process is the use of a metallic
as diamond,
commonly used
grinding steels.
is an electrolytic spindle having carbon brushes and holds the grinding
workpiece is
touches the
workpiece such that
resulting in an electro-chemical
coolant in a conventional grinding
the electrolytic fluid to the work-tool
wheel works simultaneously in the process of
thus formed further oxidize the surface of the
the formed oxides thereby exposing the fresh metal
In this process of ECG, the major material removal activity takes place by the electrolytic
grinding action
mechanical action contributes
conducting grinding wheel. The pressure
conventional grinding
of frequent wheel dressings and truing as in the
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Figure 1

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
action through 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 which otherwise are very difficul
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 cutti
In burr-free sharpening of hypodermic needles.
In grinding of super-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.


Figure 1: Schematic of ECM Grinding Process
capable of producing very smooth and burr free edges unlike
The major material removal activity in ECG process occurs by the dissolving
pieces which otherwise are very difficult to grind by the
conventional process
The parts that cannot withstand thermal damages and
The parts designed for stress and burr free applications.
The applications of ECG process include the following:
In production of tungsten carbide cutting tools.
free sharpening of hypodermic needles.
alloy turbine blades.
In form grinding of aerospace honeycomb metals.
underwater applications.
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capable of producing very smooth and burr free edges unlike
activity in ECG process occurs by the dissolving
t to grind by the
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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 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
voltage of around 10 V is applied across the electric circuit. The current density
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 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 adj
Thus control of the process parameters 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
and outlet pressure of 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 th

The general requirements of the tool material in ECM are mentioned below:
The material used in tool
The tool should be rigid enough to take up load and the fluid pressure.
The tool should be chem
The tool material should be easily formable and machinable to the desired
shape.
Copper, Brass, Titanium, Copper
commonly used electrode materials when the electrolyte is made of sod
potassium.
process can be applied to the following common methods of grinding.
Face Wheel Grinding.
Cone Wheel grinding.
Peripheral or Surface grinding.
Form Wheel or Square grinding.
Chemical Machining
circulation system.
In the ECM setup, as the gap between tool and workpiece is small, a low and
voltage of around 10 V is applied across the electric circuit. The current density
chosen is such that the shape of cathode is not changed during
at a rate of 2 to 30 m/s, through the gap between the electrodes.
sludge removal system and treatment units.
Control of ECM process refers to a predetermined adjustment of process parameters.
control parameters. The control parameters include voltage, type of electrolyte, inlet
outlet pressure of electrolyte, viscosity of electrolyte and the temperature of
the above parameters and the feed rate of the tool.
The material used in tool-making needs to be a good conductor of electricity.
The tool should be chemically inert with the electrolyte.
Copper, Brass, Titanium, Copper-Tungsten and Stainless steels are most
commonly used electrode materials when the electrolyte is made of sod
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process can be applied to the following common methods of grinding.
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
chosen is such that the shape of cathode is not changed during
at a rate of 2 to 30 m/s, through the gap between the electrodes.
ustment of process parameters.
, type of electrolyte, inlet
outlet pressure of electrolyte, viscosity of electrolyte and the temperature of
making needs to be a good conductor of electricity.
Tungsten and Stainless steels are most
commonly used electrode materials when the electrolyte is made of sodium or
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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

The ECM Process Parameters
The ECM process parameters can be subdivided into the following sub
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
or any thermal influence. The metallic workpiece is dissolved (Machined) locally thro
electricity (Electro) and chemistry (Chemical) until it reaches the 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 machin
is thus not dependent on the mechanical or physical properties of the work material. It
bronze, platinum, and tungsten carbide.
Thus the tool shape and its accuracy have a direct effect on the work piece accuracy.
The ECM Process Parameters
The ECM process parameters can be subdivided into the following sub-categories. The
Supply: Its Type, Voltage, Current and Current density.
Machine setting parameters: Working gap, Overcut and Feed rate.
Electrode material: Type of the material used.
electrolysis through which the product is processed without the tool-workpiece contact
any thermal influence. The metallic workpiece is dissolved (Machined) locally thro
dissolution by the electrochemical action. The material removal rate (or machin
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accuracy.
categories. The

workpiece contact
any thermal influence. The metallic workpiece is dissolved (Machined) locally through
dissolution by the electrochemical action. The material removal rate (or machining rate)
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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 mos
feature in ECM is that, it can machine any electrically conductive work material
irrespective of its hardness, strength or even thermal properties. The various uses of
ECM are:
o Die-Sinking operations
o Deburring operations
o Drilling operations
o Grinding operations and
o Micro-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

condition is that the material should be electrically conductive. The most important
Sinking operations
Deburring operations
Drilling operations
nding operations and
machining operations
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t important

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Electrochemical Machining (ECM)
Electrochemical machining is a method of removing
process.
It is a non-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 li
process has the capabilities 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 m

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
electrolysis (electroplating). The mechanism in ECM process is similar to electrical
discharge machining (EDM) concept
tool (cathode) and the workpiece (anode), t
However, in ECM there is no 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 not depend on
the hardness of workpiece. Soft materials can be readily used as tool materials on
harder work-pieces in ECM process since the tool doesnt wear unlike in the case of
conventional machining methods.

ECM Fundamentals
The electrolysis process being the most fundamental activity in ECM, its characteristics
are to be well understood before proceeding further into its other process details.

Electrolysis, as the name suggests is
conductors dipped in a suitable 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
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
reactions respectively.

Electrochemical Machining (ECM)
Electrochemical machining is a method of removing metal by an electrochemical
traditional machining process belonging to the electrochemical category. It is
using conventional methods. Its use is limited to electrically conductive materials. The
internal geometries can be machined with an electrochemical machine.
process. It is sometimes referred to as reverse electroplating since it removes
instead of depositing it. In the year 1833, Faraday established the laws of
(electroplating). The mechanism in ECM process is similar to electrical
machining (EDM) concept-wise, wherein a high current is passed between the
(cathode) and the workpiece (anode), through a conductive fluid (electrolyte).
in ECM there is no tool wear.
trolytically and being a chemical process, the rate of machining does not depend on
pieces in ECM process since the tool doesnt wear unlike in the case of
ntional machining methods.
Electrolysis, as the name suggests is a chemical phenomenon that occurs between two
source of direct current as shown in Fig. 3.14.1. This solution of copper sulphate is
chemical reactions occurring at the anode and cathode are called as anodic or cathodic
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metal by an electrochemical
traditional machining process belonging to the electrochemical category. It is
mited to electrically conductive materials. The
process. It is sometimes referred to as reverse electroplating since it removes
year 1833, Faraday established the laws of
(electroplating). The mechanism in ECM process is similar to electrical
wise, wherein a high current is passed between the
hrough a conductive fluid (electrolyte).
trolytically and being a chemical process, the rate of machining does not depend on
pieces in ECM process since the tool doesnt wear unlike in the case of
a chemical phenomenon that occurs between two
. 3.14.1. This solution of copper sulphate is
the anode and cathode are called as anodic or cathodic
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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
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
positive current and are referred to as the cat
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
flow of electrons, in the opposite sense to the positive current in the electrolyte, outside
the cell, as shown schematically in Fig. 3.14.2
electrolytes, the current is carried by atoms or group of atoms and not by the
attracted by the cathode and they move through the electrolyte in the direction of the
positive current and are referred to as the cat-ions. The negatively charged ions get
to the potential difference applied, the movement of ions is accompanied by the
electrons, in the opposite sense to the positive current in the electrolyte, outside
as shown schematically in Fig. 3.14.2
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electrolytes, the current is carried by atoms or group of atoms and not by the electrons.
direction of the
ions. The negatively charged ions get
is accompanied by the
electrons, in the opposite sense to the positive current in the electrolyte, outside

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In the electroplating process, which is a very popular a
metal coatings are deposited on the surface of a cathodically polarized metal. An
example of the anodic dissolution operation is electro
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 dissolved
preferentially so that after the process, the item gets shining effect and becomes flat.
The ECM and electro-polishing process are similar, such that both are anodic dissolution
processes. The rate of metal removal obtained in the electro
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
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 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 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
roughly complementary to that of the cathode will be reproduced on the anode. The
schematic of electrochemical
In the electroplating process, which is a very popular application of electrolysis, the
coatings are deposited on the surface of a cathodically polarized metal. An
the anodic dissolution operation is electro-polishing. In this polishing
workpiece which has irregularities is made as the anode in the electrolytic
gets polished and irregularities on its surface are dissolved
after the process, the item gets shining effect and becomes flat.
polishing process are similar, such that both are anodic dissolution
processes. The rate of metal removal obtained in the electro-polishing process is
At the anode, the metal dissolves electrochemically and its rate of dissolution
current and the time of current passage.
or any other metal characteristics.
the cathode, only the hydrogen gas is evolved. The electrode shape remains
being used as a metal shaping process.
Mechanism of Material Removal in ECM
e of ECM is schematically shown in Fig. 3.14.3 (a and b), the
mple an aqueous sodium chloride (table salt) solution is commonly
order to remove the products of machining, the electrolyte is pumped
the gap between the two electrodes. The rate at which metal is then removed
ately in inverse proportion to the distance between the
the machining proceeds there is a simultaneous movement of the
anode. The width of the gap along the electrode length will
steady-state value. Under such conditions, a shape which is
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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pplication of electrolysis, the
coatings are deposited on the surface of a cathodically polarized metal. An
polishing. In this polishing
workpiece which has irregularities is made as the anode in the electrolytic
gets polished and irregularities on its surface are dissolved
after the process, the item gets shining effect and becomes flat.
polishing process are similar, such that both are anodic dissolution
polishing process is
of dissolution
the cathode, only the hydrogen gas is evolved. The electrode shape remains
e of ECM is schematically shown in Fig. 3.14.3 (a and b), the
mple an aqueous sodium chloride (table salt) solution is commonly
order to remove the products of machining, the electrolyte is pumped
the gap between the two electrodes. The rate at which metal is then removed
ately in inverse proportion to the distance between the
the machining proceeds there is a simultaneous movement of the
anode. The width of the gap along the electrode length will
value. Under such conditions, a shape which is
that of the cathode will be reproduced on the anode. The
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Advantages of ECM

The major advantages of the ECM proce
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 products are obtained in
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
Am)
High dimensional accuracies are attainable

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 r
The saline electrolyte poses a risk 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. Depend
complexity of the material, the optimum product numbers 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.
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,

free products are obtained in this process.
There is no tool to workpiece contact.
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
High dimensional accuracies are attainable
The cost of tooling is high.
operates at high current and relatively low voltages (5-15V).
numbers are required for economic viability. Depending on the
material, the optimum product numbers are decided.
tendency of the electrolyte to erode away the sharp profiles.
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, high surface quality level is attainable (Ra < 0.02
ing on the
material, the optimum product numbers are decided.

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RamaKant Rana

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