Elements of Mechanical Engineering, 21ME15

ELECTROCHEMICAL MACHINING (ECM`)

• The electrolyte is pumped to the work region by means of a pump(pumps electrolyte

from the tank to other parts) through a filter(removes impurities present in the
electrolyte), pressure gauge(indicates the pressure of electrolyte coming from the pump),
flow meter(measures the discharge rate of the electrolyte) and finally, it enters into the
work region.

• An optimum gap is maintained between the tool and the workpiece. As the electrolyte
reaches the gap between anode and cathode, electrical contact is established between the
anode and the cathode

• Based on the principle of electrolysis, the positive ions from the workpiece are dissolved
and carried away by the electrolyte thus stopping it from reaching the tool and negative
ions start flowing from the tool towards the workpiece

• Chemical reaction taking place during electrochemical machining,

2H+ + 2e- = H2

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Elements of Mechanical Engineering, 21ME15

Fe = Fe++ + 2e-

Na++OH- = NaOH

Fe2++2Cl- = FeCl2

• Material removal process from the workpiece is continued until a cavity is created in the
workpiece which is a replica of the tool used in this process.

• Material is removed from the workpiece and gets settled down in the form of a slug,
which is due to the flow of electrolytes.

• The electrolyte then goes through a filtration process. In the filtration process, the
electrolyte is passed through a centrifuge where the slug is removed.

ADVANTAGES

• Suitable for hard materials

• Negligible stresses

• No heat produced

• No tool wear as there is no contact between tool and workpiece

DISADVANTAGES

• Higher cost

• Limited materials – good conductors

• Workpiece get corroded due to electrolyte

APPLICATIONS

• Used for machining hard materials

• Used for micromachining

• Used for machining turbine blades

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Elements of Mechanical Engineering, 21ME15

ELECTRO DISCHARGE MACHINING (EDM)

• Electrical Discharge machining is the process of metal removal from the work surface
due to an erosion of metal caused by electric spark discharge between the two electrodes
tool (cathode) and the work (Anode).

• Electrical Discharge Machining (EDM) is also called or known as Spark machining,

spark eroding, burning, die sinking, wire burning or wire erosion.

• Temperature range – 8000 to 120000C

• It consists of an electric power supply, the dielectric medium, the tool, workpiece, and
servo control.

• The workpiece is connected to the positive terminal and the tool is connected to a
negative terminal of the DC power supply.

• An air gap of 0.005 to 0.05 mm is maintained between the tool and the work.

• The die electric fluid which is non-conductor of electricity is forced under pressure
through the gap.

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Elements of Mechanical Engineering, 21ME15

• When a DC power is supplied, the fluid in the gap gets ionized and produces a spark
between the tool and workpiece, causing a local rise in temperature at about 1000 degrees
Celsius, when melts the metal in a small area of the workpiece and vaporizes.

• The electric and magnetic fields on heated metal cause a compressive force which
removes the metal from the work surface.

• The die electric fluid acts as a coolant carries the eroded metal particles which are filtered
regularly and supplied back to the tank.

• A servomechanism is used to feed the tool continues to maintain a constant gap between
two electrodes

ADVANTAGES

• Machining time is less than the conventional machining process

• It can be used for any hard material and even in the heat-treated condition

• High accuracy of about 0.005 mm can be achieved.

• Good surface finish can be achieved economically

LIMITATIONS

• Excessive tool wear.

• High power consumption.

• The workpiece must be an electrical conductor.

• High heat developing causing the change in metallurgical properties of materials.

APPLICATIONS

• Drilling for micro holes in the nozzle.

• Used in wire cutting.

• Engraving operation on harder materials.

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Elements of Mechanical Engineering, 21ME15

BIMETALLIC WELDING

• Bimetallic welding refers to the process of joining materials with different alloys through
welding.

• The filler material and both metals need to be evaluated before choosing the best way to
connect the metals.

• Fusion welding is a popular method, it does not work well for some combinations of
metals. Other methods may provide a more durable hold, especially for uses in high-
stress environments.

Factors to be considered in the welding process,

• Melting points of the metal

• Coefficient of thermal expansion of both metals

• Electrochemical difference

• Solubility of each material

• Final use of the welded component

TYPES OF WELDING PROCESS

Fusin welds

• Fusion welding includes traditional welding methods such as Tungsten Inert Gas (TIG)
welding and Metal Inert Gas welding (MIG)

• These processes use a filler to create the weld

• When using fusion welds, filler material must be chosen such that it matches the strength
of the weaker metal, which reduces cracking probability

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Elements of Mechanical Engineering, 21ME15

Low dilution welding

• These method includes laser weld, pulsed arc weld or electron beam to join the materials
without the need for a filler.

• Electron beam welding joins dissimilar pieces well because the high energy used avoids
problems of unalike thermal conductivities. This method works by producing very little
in the intermetallic layer and using no filler.

Non-fusion joining process

• Non-fusion joining includes processes such as friction welding, diffusion bonding,

soldering and explosion welding.

• Friction welding only melts a small bit from one of the base surfaces, heated affected
zone remains as small as possible

• This type of non-fusion welding works well when joining the following pairs of metals:

• Steel and aluminum

• Steel and copper alloys

• Stainless steel and nickel alloys

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