1909506 – UNCOVENTIONAL MACHINING PROCESS

TWO MARKS

UNIT – III

CHEMICAL AND ELECTRO–CHEMICAL ENERGY BASED PROCESS

1.Describe the principle of chemical machining process.

In chemical machining process, material is removed from the workpiece

through a controlled etching or chemical attack of the workpiece material.

2.Write the Faraday’s first law of electrolysis?

The amount of substance that undergoes oxidation or reduction at each

electrode during electrolysis is directly proportional to the amount of electricity that
passes through the cell.

3. What are the properties are expected from the electrolysis used in the ECM?

• High conductivity of electricity.

• low toxicity.
• Non-corrosive.
• chemical and electrochemical stability.
• Low viscosity and high specific heat.
5. Summarize the factors that affect MRR in ECM.

• feed rate,
• electrolyte flow rate
• voltage.

6. Define maskants in Electrochemical machining process.

Maskants (chemically resistant coatings) are used to cover the surfaces which
are not to be machined – does not allow the etchant to react and react with work
piece to dissolve it.

8. Summarize the application of ECM.

• Machining complicated profiles.

• Drilling small deep holes.
• Machining of hard materials and heat resistant materials.
• Machining of cavities and holes of irregular shapes.

10. How the current density affects the MRR.

As discharge current increases, metal removal rate increases and surface finish is
degraded. Surface finish is usually degraded due to an increase in metal removal
rate.
 11. Name the electrolytes which are used in electro chemical machining.

• Sodium chloride.
• Sodium chromate.
• Sodium hydroxide.
• Potassium nitrate.
• Sodium sulphate.

12. Discriminate the process of CHM and ECM.

Chemical Machining (CHM) Electro-Chemical Machining (ECM)

As the name suggests, CHM is one It is one electrical energy based NTM
chemical energy based NTM process. process.

Here material is removed in ionic form due Here also material is removed in ionic form
to controlled dissolution by chemical but due to controlled electro-chemical
etchant. Etchant slowly dissolves metal to dissolution of work metal.
realize machining.

It is independent of electrical conductivity The workpiece must be electrically

of workpiece metal, so it can be applied for conductive as it is used as anode of the
conductive and non-conductive materials. electrolytic cell.

13. What is etchant in chemical machining process?

The Etchant is the chemicals used in the chemicals machining process, which
dissolves the workpiece & removes material by chemical reactions.
To avoid uneven material removal from the workpieces – a fresh etchant is
continuously sprayed, or the workpieces are submerged in an etchant tank.

14. Summarize the advantages of ECM process.

• Material removal rate is high compared to conventional machining process.

• Wear and tear of the tool is negligible.
• The machined work surfaces are free of stress
• No cutting forces are involved in the process.
• High surface finish.

15. Differentiate the advantages of ECG over conventional grinding.

• Tool wear is negligible. So, the tool of grinding wheel is increased/.

• Good surface finish is obtained.
• Burr free components are produced.
• As compared to conventional grinding, a very little cutting force is applied to
the work piece.

16. List the application of electro chemical grinding.

• Very precision grinding for hard metals like tungsten carbide tool tips, high
speed steel tools.
• Cutting thin sections of hard materials without any damage or distortion.
17. Summarize the parameters that affect the material removal rate in Electro-
chemical Grinding.

• Current density.
• Electrolyte.
• Feed rate.
• Grinding wheel speed.

18. Quote the main difference between electroplating and ECM.

ELECTROPATING ECM
Material removed from the work piece. Metal deposited on the work piece
Workpiece connected to positive terminal Workpiece is connected to negative
and the tool is connected to negative terminal and tool is connected to positive
terminal. terminal.
When the current passed the workpiece Tool loses material and the metal deposited
loses metal and the dissolved metal is on the work piece.
carried out by circulating an electrolyte
between work and tool.

19. Define the principle of electro chemical grinding process.

In electrochemical grinding method, the work is machined by the combined

action of electrochemical effect and conventional grinding operation. But the major
portion of the metal (about 90%) is removed by electrochemical effect.
20. What is meant by electro chemical honing process?

Electrochemical honing is one of the most precision machining processes used

for finishing of cylinders and gears, based on the combination of electrochemical
machining and conventional honing process.

21. List the advantages of ECH process.

• Increased MRR particularly on hard materials.

• Since most of the material is removed electrochemically, honing stone life is
greatly extended.
• Burr-free operation.
• Unlike conventional honing, no micro-scratches are left on the work surface.
• Less pressure required between stones and work.

22. Define surface roughness.

Surface roughness is a component of surface texture and plays an important

role in determining how an object will interact with its environment. Roughness is a
good indicator of the potential performance of a mechanical component, since
irregularities on the surface may form nucleation sites for cracks or corrosion.
23. List the process parameters of ECG process.

• Current density.
• Electrolyte.
• Feed rate.
• Grinding wheel speed.

24. List the application of ECH process.

• Due to rotating and reciprocating honing motion, the process reduces the
errors in roundness through the rotary motion.
• Taper and waviness errors can also be reduced
• Typical applications are the finishing of cylinders for internal combustion
engines, air bearing spindles and gears.

25. What are the factors to be considered while designing the tool?

• Types of workpiece material.

• The degree of accuracy and precision required
• Types and sequence of operation need to be performed.
• Environment – What kind of environment and its effects on the tool, example
dry, wet, corrosive, etc.
• Size and type of machine tool.

• Number of components to be made and how many times a single tool needs
to perform its operation.