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Published by: Thangadurai Senthil Ram Prabhu on Sep 11, 2013
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1. The composition (% by weight) of nomonic 75 alloy is given in the accompanying table: Element % by weight Atomic Weight Valency Density

Ni 72

Cr 20

Fe 5

Ti 0.5

Si 1 28.09 4 2.33

Mn 1 54.94 2,4,6,7 7.43

Cu 0.5 63.5 1,2 8.96

58.71 51.99 55.85 47.90 2,3 8.9 2,3,4 7.19 2,3 7.89 3,4 4.51

Calculate MRR (specific MRR and volumetric MRR) when a current of 2000 A is used. Use the lowest valency of dissolution in each case. Determine the equilibrium gap if applied voltage = 15V, Over potential =1.5 V , specific resistance = 0.21 ohm cm and feed is 1mm/min Calculate the rise in temperature for the following machining conditions: feed rate =0.05 mm/s, room temperature =38 deg, electrolyte density = 1.05 g/cm3 , efficiency = 100 %. Electrolyte flow rate = 120 LPM. Flow velocity = 2000 cm/s and specific heat = 1.06 cal/g C. Geometry of the work piece surface with single curvature is given by the following equation y = 10 x0.20x -0.05 x2, where x and y are in centimeters. The following details are as follows: Applied voltage =15 V. Over potential =0.67 V, feed rate = 0.75 mm/min, work material = copper (atomic weight = 63.57 and valency = 1) density = 8.96 g/cm3 . specific resistance = 0.2 ohm cm




6. Show that in a constant current ECM drilling process, the hole size decreases inversely as a function of square root of feed rate.

8. What is Joule heating as applied to ECM. 62% nickel. Calculate the machining rate and electrode feed rate for the following data for the electrolyte . In a ECM process. Faradays constant may be taken as 96540 coulombs.71 Chromium 51. Practice problems 1. valency = 2.A dc power supply of 18 Volts and 5000 A was used in ECM using copper electrode and sodium chloride solution.5 cm was maintained.87 g/cm3. for machining of iron. a metal removal rate of 1cm3 /min is desired. Its valency 2 and density 7. density = 7. The data for Iron anode may be taken as: Atomic weight = 56. 2. derive an expression for the flow rate of electrolyte to prevent boiling and velocity of the electrolyte flow. Metal Gram Atomic Weight Cobalt 58. The following data is available.8 gm/cm3.99 Faraday’s constant = 96500 coulombs /mole Valency 2 2 6 3. A tool work gap of 0. during electro chemical machining with a current of 500 amperes. Determine the necessary current.28 gm/cc. in a constant feed rate ECM system. assume atomic weight of iron to be 56. Prove mathematically that. Estimate the MRR of an alloy containing 18% cobalt. the machining process is inherently self regulated since the MRR tend to approach the feed rate.63 Nickel 58. The density of the alloy is 8. 20% chromium.7.

if the maximum permissible temperature of electrolyte is 95 deg and ambient temperature is 30 deg.17 J/g-k. Applied voltage is 12 V.54 x2. An ECM with copper electrode and NaCl as electrolyte is used for machining of iron. Electrode work gap=0.54 cm.4. Estimate the permissible fluid flow velocity. The electrolyte properties are : specific heat= 4. Calculate the maximum MRR if the current density is 160 cm/cm2 . The ECM has the following dimensions: Electrode area = 2. Density= 1g/cm3. specific resistance = 3 ohm cm.0254 cm.

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