EXPERIMENT NO.

: 3
• Objective: A detailed study report on working principle, setup, process parameters,
advantages, dis-advantages and applications of Electro Chemical Machining.

• Apparatus: Electro Chemical Machine.

• Introduction:
Electrochemical machining is a modern machining process that release on the removal of work
piece atoms by electrochemical dissolution (ECD) in accordance with the principal of Faraday.

Fig: Machine of Electro Chemical Machining

• Working principle:
▪ Principal of electrolysis:
Electrolysis occurs when an electric current passes between two electrodes dipped into an
electrolyte solution. The system of electrode & electrolysis is referred to as electrolysis
shale. The chemical reaction which occurs at the electrode are called anodic or cathodic
reaction. ED of the anodic work piece forms the basis of ECM of metals. the amount of
metal dissolved is calculated from the amount of metal dissolved is calculated from farads
law of electrolysis which states that:
i. The amount of mass dissolved m is directly proportional to amount of electricity.
ii. The amount mass dissolved is proportional to substance chemical equivalent weight.
▪ Principle of electrochemical machine:
Electrochemical machining uses a direct current at high density of 0.5- 5 amp/m2 and a low
voltage of 10- 30 V. The machining current passes through the electrolyte solution that fills
 10. Pump: There are two pumps used namely A and B. Pump A is used to draw electrolytes
from the reservoir tank and pump B is used to supply the electrolyte to the reservoir
tank.

11. Filter and Centrifuge: A filter is used to filter the electrolyte reaching the reservoir
tank. And prevents the accumulation of excess electrolytes. The function of a centrifuge
is to separate the slug from the electrolyte.

12. Slug Container: A slug container is used to store the slug which is separated from the
electrolyte. This slug can be used for various experimental purposes.

Fig: Electro-Chemical Machining Setup

• Important process parameters:

i. Nature of power supply:
▪ Type: Direct current.
▪ Voltage: 2 to 35 volts.
▪ Current: 50 to 40000 amp.
▪ Current density: 20A/cm2 to 300A/cm2
▪ Material removal rate directly proportional to current.
▪ Electrolyte temperature increase.

ii. Duty cycle:

▪ At a duty cycle of 0.3 the surface has its best surface roughness.