Somali National University

Faculty: Engineering

Department: Mechanical

Course: Machine Tool

Topic: ECM

Student name: Abdihakin Ali Muse [ ID 386]

SUBMISSION DATE

October,30, 2023
 TABLE OF CONTENTS

ELECTROCHEMICAL MACHINING ......................................................................................... 2

Introduction: ................................................................................................................................ 2

Electrochemical machining principle: ........................................................................................ 2

Electrochemical Machining Equipment & Construction: ........................................................... 4

Working of Electrochemical Machining:.................................................................................... 6

How The Cuting Tool Of Electrochemical Machining Work: ................................................... 7

Advantages:................................................................................................................................. 8

Disadvantages: ............................................................................................................................ 8

Applications: ............................................................................................................................... 8

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 ELECTROCHEMICAL MACHINING

Introduction:

Electrochemical machining (ECM) Is a machining process in which electrochemical process is

used to remove materials from the workpiece. In the process, workpiece is taken as anode and
tool is taken as cathode. The two electrodes workpiece and tool is immersed in an electrolyte
(such as NaCl). When the voltage is applied across the two electrodes, the material removal from
the workpiece starts. The workpiece and tool is placed very close to each other without touching
In ECM. the material removal takes place at atomic level so it produces a mirror finish surface.

Electrochemical machining principle:

Electrochemical machining works based on Faraday’s laws of electrolysis. The amount of metal
removed by machining or deposited is calculated from faraday’s laws of electrolysis Which
states that The amount of mass removed by machining m is directly proportional to the amount
of electricity.
m ∝ It

The amount of different substances dissolved m by the same quantity of electricity(It) is

proportional to the substance’s chemical equivalent weight.

m∝∈

Where ∈ = Chemical equivalent weight.

ECM uses direct current at a high density of 0.5 to 5 A/mm² and a low voltage of 10 to 30V. The
machining current passes through the electrolytic solution that fills the gap between an anodic
workpiece and a pre-shaped cathodic tool. The electrolyte is forced to flow through the inter-
electrode gap at a high velocity, usually more than 5m/s to intensify the mass and charge transfer
through the sublayer near the anode. The electrolyte removes the dissolution products, such as
metal hydroxide, heat, and gas bubbles, generated in the interelectrode gap.

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The example of the dissolution reaction of iron in sodium chloride(nacl) water solution as an
electrolyte. The result of electrolyte dissolution and Nacl dissolution leads to

The negative charge anions OH– and Cl– moved towards the anode and positively charged
cations of H+ and Na+ are directed to the cathode. At the anode, Fe changes to Fe++ by losing
two electrons.
Fe→ Fe++ + 2e
At the cathode, the reaction involves the generation of hydrogen gas and hydroxyl ions.

2H2O+2e→H2 +2(OH)–

The outcome of these electrochemical reactions is that iron ions combine with other ones to
precipitate out as iron hydroxide, Fe(OH)2

Fe+2H2O→Fe(OH)2+H2

The ferrous hydroxide may react further with water and oxygen to form the ferric hydroxide,
Fe(OH)3

4Fe(OH)2+2H2O+O2→4Fe(OH)3

With this metal electrolyte combination, electrolysis has involved the dissolution of iron, from
the anode and the generation of hydrogen, at the cathode.

Figure 1: A schematic view of reactions taking place in the Electrochemical machining process

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Electrochemical Machining Equipment & Construction:

There are several electrochemical machining equipment used to construct the electrochemical
machine in the electrochemical machining process.

 Dc power supply
 Table
 Workpiece
 Tool
 Feed Unit
 Electrolyte
 Pump
 Filter
 Pressure gauge
 Flow Meter

Dc power supply:

The DC power supply used in this process is from 3 to 30V. The DC power supply is used to
create a potential difference between the workpiece and the tool and make them act as anode and
cathode respectively.

Table:

The table used to hold the workpiece on the top of it.

Workpiece:

This is the object from which material is to be removed. The workpiece is connected to the
positive terminal of the DC power supply and acts as an anode.

Tool:

This tool is connected to the negative terminal and acts as a cathode. The too(cathode) should
have good thermal conductivity and electrical conductivity and also should be corrosion proof.
The most commonly used tools in the ECM machining process are stainless steel, brass, copper,
etc.

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Feed Unit:

It is used to constantly move the tool downward towards the workpiece.

Electrolyte:

The electrolyte is used to establish an electrical connection between the anode and the cathode so
that positive and negative ions flow from these two. The electrolyte is used to remove the heat
produced from the passage of the current. The most commonly used electrolyte used in the ECM
process is salt electrolytes like sodium chloride and sodium nitrate.

Pump:

This pump is used to pump the electrolyte towards the gap between the cathode and anode.

Filter:

The filter is used to filter the electrolyte and remove the unwanted particles from the electrolyte.

Pressure gauge:

The pressure gauge is used to control the pressure at which the electrolyte is supplied to the
system of electrochemical machining.

Flow Meter:

Flow meter is used to regulate the flow of electrolyte which is supplied to the system.

Figure 2: Electrochemical Machining

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Working of Electrochemical Machining:

It is the method of removing metal from the electrochemical process, where DC current is passed
between the tool(cathode) and workpiece(Anode) through an electrolyte, known as ECM
machining. In this process, a combination of electrical energy and chemical energy is used to
remove materials from the workpiece. The ECM technique is most frequently used to create
complex geometries.

 First, the workpiece is assembled in the fixture and the tool is brought close to the
workpiece. The tool and workpiece is immersed in a suitable electrolyte.
 After that, a potential difference is applied across the w/p (anode) and tool (cathode). The
removal of material starts. The material is removed in the same manner as we have
discussed above in the working principle.
 Tool feed system advances the tool towards the w/p and always keeps a required gap in
between them. The material from the w/p comes out as positive ions and combine with
the ions present in the electrolyte and precipitates as sludge. Hydrogen gas is liberated at
the cathode during the machining process.
 Since the dissociation of the material from the w/p takes place at atomic level, so it gives
excellent surface finish.
 The sludge from the tank is taken out and separated from the electrolyte, The electrolyte
after filtration again transported to the tank for the ECM process.

Figure 3: Electrochemical Machining Equipment

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How The Cuting Tool Of Electrochemical Machining Work:

Electrochemical Machining (ECM) can cut small or odd-shaped angles, intricate contours or
cavities in hard and exotic metals, such as Titanium Aluminides, Inconel, Waspaloy, and high
Nickel, Cobalt, and Rhenium alloys. Both external and internal geometries can be machined.
In the ECM process a positively-charged (cathode) cutting tool is advanced into a negatively
charged (anode) Workpiece, Pressurized electrolyte is injected at a set temperature into the area
being cut at a feedrate equal to the rate of liquefication of the anode material. The gap between
the tool and the workpiece varies within 80–800 micrometers (0.003–0.030 in) as electrons cross
the gap between the tool and workpiece material from the workpiece is dissolved as the tool
forms the desired shape in the workpiece. The electrolytic fluid carries away the metal hydroxide
formed in the process. In ECM there is no tool wear The ECM cutting tool is guided along the
desired path close to the work but without touching the piece. However no sparks are created,
High metal removal rates are possible with ECM, with no thermal or mechanical stresses being
transferred to the part, and mirror surface finishes can be achieved. There is neither tool wear nor
plating of the work material on the tool, so one tool can produce a very large number of
components in its life.

Figure 4: A schematic view of electrochemical discharge machining (ECDM)

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Advantages:

Here are some electrochemical machining advantages, given below-

 It can cut any materials irrespective of their hardness, strength or toughness.

 Complex cavities can be produced using ECM machining.
 Tool wear is zero as there is no direct contact between the tool and the workpiece.
 A very good surface finish is produced in this process as the material removal takes place
due to atomic level dissociation.
 Very little heat is generated during this process.
 No residual stresses as there is no direct contact between the tool and the workpiece.
 There is no thermal damage to the workpiece.

Disadvantages:

Here are some of the electrochemical machining disadvantages, given down-

 Only electricity conductive material can be machined.

 It can not be used for machining soft materials and non-metals.
 The original problem of poor dimensional accuracy
 Environmentally polluting large waste
 The acidic electrolyte poses the risk of corrosion to tools, workpieces and equipment.
 High energy consumption

Applications:

Some of the electrochemical machining uses given down:

 Sinking operations
 Drilling
 Trepanning
 Profile and contouring
 Micro-machining

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