Hybrid

Electrochemical Discharge
Machining(ECDM)
Presented by
Ajay Vaishnav
TME15B001
 Contents:-
Introduction
Need of ECDM
Working Principle of ECDM
Material Removal Mechanism in ECDM
Main Influencing parameters
Advantages over ECM/EDM
Disadvantages over EDM/ECM
Application of ECDM
Comparison between ECDM, EDM and ECM
 What is ECDM ?

ECM • Electro-Chemical
process

• Hybrid Thermal
ECDM process

EDM • Electro-Thermal
process

3
 • Material removal due to Erosion of
EDM work piece at high temperature and
high pressure.

ECM • Material removal due to Anodic

dissolution of work piece.

• Material removal due to Thermal

ECDM heating/melting and chemical
etching of the work piece.
4
Introduction
Electro-chemical discharge machining (ECDM) is a
hybrid non-conventional manufacturing process which
combines the features of electro-chemical machining
(ECM) and electro discharge machining (EDM). Non-
conducting materials can be machined by ECDM by
employing auxiliary electrodes.

5
 Need of ECDM

1.High Accuracy and Surface Finish

2.High Strength Alloys
3.Complex Surfaces
4.Technology Advancement
5.Machining on non-conducting
materials
 Material Removal Mechanism
in ECDM :-
MRR
Mechanism

Thermal mode Chemical

mode

Melting Vaporization Etching/E-C

Rxn
Mechanism

(auxiliary
electrode)
 BASIC MECHANISM OF
Electro-chemical discharge machining
(ECDM)
The tool electrode (cathode) and auxiliary electrode
(anode) are immersed in an electrolyte solution (typically
NaOH or KOH). Both electrodes are connected to a DC
power supply, causing hydrogen bubbles to be produced on
both electrodes due to electrochemical reactions. The
bubbles become dense and coalesce into a gas film
(Passivating Film) on the tool electrode. The gas film allows
sparking between the tool electrode and electrolyte by
isolating the tool from the surrounding electrolyte. If the
workpiece is brought close to the tool, material removal
occurs.
Main Influencing parameters :-
 Electrolyte Semi Dielectric
fluids/Electrolyte
 Voltage 40-150V, DC & Current 3-4A
 Gas Film (Passivating Film)
 Spark Generation
 Tool Electrode
 Auxiliary Electrode
 Electrode Gap
 Tool Properties
 High Electrical & Thermal conductivity
 High melting point
 Cheapness
 Good wear resistance Eg. Steel,Cu

1.Cylindrical Tool (Conventional Tool)

2.Tapered Tool
12
 Why Tapered Tool Electrode?

 Fringing effect
• Current density is more intense near the rim for
cylindrical tools. Thus, sparks tend to generate
from any point along the rim of the tool electrode,
if not considering any geometrical defects.
By replacing the cylindrical tool with a tapered
end tool, we make discharges focus on a
concentrated region. 13
Tapered tool electrodes with different shape

14
Some Other Tools
 Effect of Voltage
 Increase in applied voltage increases the MRR
 But Less than 100V is best.

Question: Why Higher voltage is not preferred ?

Ans.: MRR start decreasing due to entrapping of

debris in spark gap
 Function of Electrolyte
 Maintain constant resistance across
the gap
 Cools the spark region
 Removes eroded particles
 Avoid welding of tool and work
 Examples:- aqu solution of KOH or
NaOH, sodium silicate or nitrate
 Effect of Electrolyte
Concentration
 Concentration  MRR 
 Concentration  Smoother
Surface finish

 But concentration(typically NAOH) <

250g/L
 Why ????
 Some More Parameters

 Effect of machining gap

 Effect of inter electrode gap

 Effect of tool feed rate

 Effect of Electrolyte temperature

 Advantages over ECM/EDM
:-

• The surface obtained have better finish

than EDM and ECM 0.01mm or 10 m
• Suitable for non-conducting materials.
• High accuracy.
• Does not leave any chips or burrs.
• Less power consumption.
 Advantages over Traditional
Processes
 Non conducting materials like glass, ceramics etc can be
machined in this process.

 Tool wear is negligible compared to other processes.

 Focused spark generation due to the tapered tool.

 High machining rates are also possible that increasing the

productivity and reducing the unit production cost.
21
Disadvantages over EDM/ECM:-
• Tool is likely to worn out, if the machining time is increased.
• Energy from the spark is not fully transferred.
• Initial cost is high.
• Thickness of ceramic material can be machined is limited to 1.5 mm.
• Radial overcut.
• The process cannot produce internal and external sharp edges.

What is Radial Overcut ?

 Application of ECDM :-
production of :
• Through and blind micro-holes
• Micro-grooves
• Micro-slots
• Micro-channels and Complex shapes produced in non-conducting
materials ( quartz, glass, and ceramics) etc.
• Miniature features of turbine blades
• Industrial applications like bearings, computer parts
Comparison between
ECM, EDM and
ECDM ASPECTS ECM EDM ECDM

PRINCIPLE Anodic dissolution Spark erosion Both

POWER 10,000A,2-3V,DC 200A,50-200V,DC 3-4A,40V,DC

WORK Conductive Conductive Conductive &

PIECE non- conductive
MRR Less Less 5times faster
than EDM
TOOL Less than both Higher than ECDM Less than EDM
WEAR
ACCURACY Higher than EDM Dimensional accurate +-.01mm
:+-.03mm
SURFACE Higher than both Less Higher than
FINISH EDM
COST Less initial than ECDM Less initial than High
ECDM
 …..

Questions

Please
25