CHEMICAL MACHINING

Introduction
The chemical machining process is also knowns as the Etching process. This process
sounds like magic due to its easy outputs. In this process, we are just dipping the workpiece
into a tank of chemical solution and in just a few seconds, we will be obtaining the desired
structure on the workpiece. This machining process is not magic, but scientifically
practical. This process uses a strongly acidic or alkaline chemical reagent to remove
material from the workpiece. This is an age-old process when organic chemicals such as
citric acids and lactic acids were used to etch metals to manufacture the desired shape of
armors. Chemical machining is a process of material removal to obtain a desired shape on
the workpiece by dipping the workpiece into a strong chemical reagent.

Chemical Machining Construction or Parts:

It consists of the following parts:

Tank
Heating coil
Stirrer and
Workpiece

1. Tank:
This process has a tank with its face open. The tank is built of strong metal coated with
materials that are non-reactive to etchant depending on the applications and
concentration of chemical reagent.

2. Heating coil:
A heating coil is mounted at the lowest section of the tank to maintain the temperature of
the tank at a constant level. It is practical that in any metal removal process the heat
generation is natural. Also, the coil does cooling in necessary conditions.

3. Stirrer:
A stirrer is placed in the etchant whose main purpose is to mix the etchant consistently to
maintain a uniform concentration and heat along the volume of the etchant. It is well
known to us that the hot particles always accumulate at the top, leaving the cold below.
So, to spread the heat uniformly along the etchant, the stirrer is used. The stirrer also
helps in the flushing of dissolved metal from the workpiece simultaneously breaking the
bubbles formed during machining due to oxidation.

4. Workpiece:
The workpiece is held in the etchant by the use of a hanger in the case of small
applications. The length of the hanger is fastened over a masked area so that the fixing of
the workpiece does not disturb the machining zone. In the case of a larger workpiece,
fixtures coated with rubbers and polymers are used to hold the workpiece.

Working Principle:
The working principle of chemical machining is based on chemical etchant. An etchant is
a mixture of strong chemical acids which are reactive to metal. When the workpiece is
dipped in the etchant, the etchant reacts with the workpiece causing a uniform rate of
dissolution of metal from the workpiece. To obtain a desired shape or structure, an
elemental coating that is non-reactive to a chemical reagent called ‘Maskant’ is applied
on the workpiece before machining. Localized machining is achieved by applying a
suitable mask on all the areas where we do not want the etchant to react. Thus, exposing
the machining zone for the necessary removal of metal.
Chemical Machining involves four major processes performed
in a series:

1. Cleaning:

Cleaning is a preparatory process to ensure that the surface of the workpiece is free
from contaminants, rust, and foreign particles. It is usually performed by high-
pressure water jets, alcoholic solutions, and diluted HCl.

Needs of cleaning:

Improper cleaning results in poor adhesion of maskant, inaccurate final dimensions

and improper dissolution of metal.
Contaminants like oil, grease can lead to oxidation.
Improper cleaning can result in peeling of maskant letting etchant flow beneath the
mask does spoiling the geometry.
Foreign particles could lead to the formation of scales.

After the washing of the workpiece, the workpiece is dried under hot air blowers. The
cleaning process is always carried out in advanced CNC machinery.

2. Masking:
It is a process of applying maskant over the surface of the workpiece. A layer of polymer
or rubber is coated on the workpiece. Masking is done to prevent the area which does not
require machining from the etching process. Masking is done all over the workpiece
except the areas to be machined.

3. Etching:
This is the process in which the required metal removal takes place. After perfect
masking, the workpiece is dipped into the tank of the chemical reagent with the heater
and the stirrer turned ON.As soon as the workpiece is dipped, the etchant starts to react
with the non-masked areas of the workpiece. The highly concentrated acid begins to react
with the workpiece altering its chemical features.This reaction causes the predefined
portions to melt and separate from the workpiece layer by layer.
In this process, the depth of cut is directly parallel to the time for which is the workpiece is
dipped. The more time the workpiece is in the etchant, the more metal is removed. The
less time, the less is the depth of cut. This is calculated by the formula.

E=S/T

Where,

E = Etch rate.
S = Depth of cut required.
T = Time in seconds.

The values of etch rate are precalculated by experimentations. Etch rate is consigned
with the concentration of chemical reagent and the type of workpiece to be machined.
The depth of cut is obtained in the design. Hence, the time can easily be calculated before
immersion of the workpiece in the etchant.

4. Demasking:
Demasking is a process of peeling off the maskant that was applied before the etching
process. Once the maskant is removed from the workpiece, the workpiece is again sent to
cleaning operation where any leftover etchant is washed away by pressurized cold water.
The workpiece is then dried up and ready for final dispatch.

Chemical Machining Operation Types:

1. Chemical milling (CHM): This operation is performed to obtain pockets, contours
on the workpiece or to remove bulk material from the workpiece.

2. Chemical engraving (CHE): This operation is performed to reproduce a special

design on a workpiece with a lot of precision. E.g., titles, brand names, serial numbers,
etc.

3. Chemical polishing (CHP): This operation is performed to make up a fine finishing

or deburring of the workpiece. This is possible by using of usage of lighter diluted
chemical reagent.

4. Photochemical machining (PCM): Photochemical machining is a process of

manufacturing stress-free and crack-free components. PCM is used where micro details
are to be machined on a workpiece.This process uses Chemical machining (CHM) as its
primary technique to remove material and photo-resistive mask for designing purposes. PCM is
an advanced machining process whose root is Chemical machining.

Chemical Machining Applications:

The following application includes:

Weight reduction of complex contours, impossible by conventional methods.

Machining of thin and delicate components.
Used to machine the contours present inside a hole.
Used in automobile and aviation industries.
Making of fine screens and meshes.
Removal of metal where the holding of a workpiece is difficult.

Chemical Machining Advantages:

The following advantages include:
This machining process removes metal uniformly.
Good surface finish with close tolerances.
Complex contours can be easily machined.
Material removal along all the axes at the same time.
Less skilled operator is required.
 No mechanical stress is produced on the workpiece.
Low initial cost.
Low machining cost.

Chemical Machining Disadvantages:

The following disadvantages include:

Less operator safety, a minor spill of etchant on the skin can cause harm to the
operator.
Chances of corrosion after the days of machining.
Machining of alloys can lead to poor surface finish.
Process is not eco-friendly.
Disposal of byproducts can cause harm to the surrounding.
Material Removal Rate (MRR) is less in comparison with other machining
processes.
Chances of bubble formation, which may result in improper machining.

Important Parameters:
Maskant: Maskantcan is defined as a material used to coat the workpiece for preventing
the portion of the workpiece from etching.

Factors to consider to select the type of maskant:

It should be inert to the chemical reagent used.

Tough to withstand handling.
It should not change its characteristics during the machining process.
Also withstand heat.
It should allow itself for cutting and
scribing. It should adhere well to the
workpiece.
Availability and low cost.

Workpiece material Maskant material

Aluminum and its alloys Butyl rubber, Polymer, and Neoprene

Copper and its alloys Polymer

Iron-based alloys Butyl rubber and Polymer

Nickel Neoprene

Magnesium Polymer

Titanium Polymer
 Table: Maskant materials suitable for machining common metals.

Chemical Machining Maskant technique:

There are three major techniques to apply maskant on a workpiece.

1. Cut and Peel:

In this maskant technique, the workpiece to be machined is first dipped into a tank of
liquid maskant, similar to coating. Once the whole workpiece is coated, the workpiece is
taken out and left to dry for a few minutes. Then, a scriber is used to cut the layer of
maskant applied to the workpiece.The cuts are precisely made according to the design to
be machined. Once the cutting operation is done, the maskant is removed from the areas
to be etched. Thus, the cut and peel masking technique works.
This maskant technique involves the use of relatively thick materials like neoprene, butyl,
and vinyl-based materials. This technique is exclusively used for chemical milling
operations (CHM).

Over the era, this technique has eased the production of missiles, aircraft, and their
structural parts. Due to the inert nature of maskant and thickness involved in this process
of about 0.5 inches or more, this technique gives access to extremely high chemical
resistance. The major negotiation in this technique is only that, this technique has
relatively low-quality tolerance.

Materials used in the cut and peel masking technique are Vinyl, neoprene rubber, butyl
base materials, bee wax, Burgundy pitch applied by flow or dip or by spray coating. The
thickness of these maskants ranges from 0.03 to 0.13 mm.

2. Screen Print:
This technique makes use of conventional silk-screen print technology. In this mask
application, fine mesh silk or stainless-steel screens are deployed on the workpiece.
Similar to the printing of radium on a wide sheet, here, in this technique, a whole of
design is printed on a silkscreen and SS meshes. The mesh is then pressed against the
surface of the workpiece. This completes the marking of areas to be machined.

Then, a layer of maskant is rolled on the whole of the workpiece. The adhering of
maskant on the workpiece is achieved by drying and baking, Once the maskant adheres
to the workpiece, the installed meshes are removed from the workpiece, which results in
the removal of the mask from the areas to be machined.

Screen printing is a fast, economical masking technique for large-scale productions. This
technique also gives access to a greater degree of accuracy.

The mask thickness is always less than 0.05 mm. This maskant technique is best suitable
for parts less than 1.2m × 1.2m with flat surfaces and moderate contours.

3. Photo-resist:
The photo-resist masking technique is exercised in the Photochemical machining process
only. This technique is so versatile in this autonomous era.

The use of the photo-resist masking technique switches the process of chemical
machining into a different non-traditional machining process i.e., the Photochemical
machining (PCM) process.

In this technique, a picture of the end product design is printed on a film of photo-
sensitive material. The film has a character to attract and reflect the rays of ultraviolet
light.
The printed film is carefully and accurately placed on the sheet metal (workpiece) to be
machined and then the workpiece is passed through a machine of UV.

Between the IN and OUT of the workpiece, due to the character of the film to allow and
reflect the UV light to pass, only the pre-printed zone or marks on the film allows the UV
to pass through the film to the workpiece.

This exposure of the workpiece to the UV smoothens the definite parts that were pre-
designed for chemical machining. The rest of the process is carried out in the
Photochemical machining process.

The material used in this technique hardly has its thickness ranging between 1.27mm to
1.5mm. This technique is widely used in the manufacturing of PCB, semiconductors,
electronic chips, computer metallic components, small gears for watches, etc.

Etchant:
The etchant can be defined as a mixture of chemical acids diluted or concentrated that
can react with metal and dissolve it.

Workpiece Etchant Operating temp. Etch rate (mm/min ×

material (oC) 103)
 Aluminum and its Na (OH) 49 20-30
alloys

FeCl3 49 13-25 13-25

Brass or bronze NH4HF2 27 10-15

FeCl3 49 25 25

Lead FeCl3 54

Magnesium alloy HNO3 32-49 25-50

Nickel FeCl3 49 13-38

Titanium HNO3HF Ambient 13-25

Table: Etchants suitable for machining common metals.

Electrochemical Machining

Electrochemical Machining (ECM), characterized as non-traditional

machining, is an advanced machining, non-contact, reverse electroplating
process (ECM
removes material instead of depositing it). In ECM, a high electric current is
passed between the tool and workpiece through a conductive fluid. The high
current and the conductive fluid are used to ionize and remove the metal
atoms of the workpiece yielding a burr-free surface.

In conventional or traditional machining processes, the tool material has to be harder than
the workpiece material. But the striking feature of Electrochemical Machining being
independent of strength, hardness, and toughness of workpiece material makes it
suitable for machining of any conductive material and also machining complex cavities in
high strength materials.

The electrolysis process is the most fundamental activity of ECM based upon “laws of
electrolysis (electroplating)” formulated by Faraday in 1833.

Electrolysis is a chemical phenomenon that occurs between two conductors dipped in a

suitable solution when an electric current is passed between them.

In solid conductors, the current is carried by electrons.

In electrolytes, the current is carried by atoms or a group of atoms. Atoms are called ions
when they acquire positive or negative charge upon losing or gaining electrons
respectively. Positive ions (cations) are attracted by the cathode, in the direction of
positive current through the electrolyte, and negative ions(anions) are attracted to the
anode.

This setup of electrodes and electrolytes is called electrolytic cell.

Electrochemical Machining Parts or Construction:
Electrochemical Machining consists of following main parts:

Power supply:
Voltage must be kept low to avoid short-circuit because the gap between the tool and
workpiece is low for high-pitched correctness

Material removal rate ∝ Current density. Therefore, high current values are used for the
ECM process.

The following are the power supply parameters for the ECM process:

a. The power source is electrical in ECM

b. Type: Direct current
c. Current capacity: 50 to 40,000 A
d. Voltage kept small (to prevent short-circuit) : 2- 35 V

Electrolyte:
Electrolytes are conductive fluid and are selected in parity with electrodes. Some
electrolyte-electrodes combination is given below:

Sodium chloride (NaCl) at a concentration of 20% is used for ferrous alloys.

Sodium nitrate (NaNO3) is used for ferrous alloys.
Hydrochloric acid (HCl) is used for Nickel alloys.

A mixture of sodium chloride (NaCl)and sulphuric acid (H2SO4) makes use for nickel
alloys.
A mixture of 10% hydrofluoric acid (HF), 10% hydrochloric acid (HCl), 10% nitric acid
(HNO3) applied for Titanium.
Sodium hydroxide (NaOH) is for tungsten carbide (WC).

SL NO Alloy Electrolyte
1. Iron based Chloride solutions in water
(mostly 20% NaCl)
2. Ni based HCL or mixture of brine and
H2SO4
3. Ti based 10% hydrofluoric acid + 10%
HCL +10% HNO3
4. Co-Cr-w based Nacl
5. WC based Strong alkaline solution

Electrolytes must have the following properties:

1. High conductivity
2. Low viscosity
3. Low toxicity and corrosivity
4. Chemical and electrochemical stability for better material removal rate.

3 functions of electrolyte are:

a. Carries current between the tool and workpiece

b. Removes the product from the internal electrode gap
c. Removes the heat produced due to passage of the current.

Electrolyte parameters in ECM are as follows:

Temperature : 20 °C – 50 °C
Flow rate: 20 litres/min per 100 A current
Pressure: 0.5 to 20 bar
Dilution:100 g/l to 500 g/l

Electrolyte Flow Arrangement in Electro Chemical Machining

Proper electrolyte circulation is essential for accurate machining in ECM process.
The tool must be properly designed to permit a uniform electrolyte flow in all
machining areas.
Insufficient or excessive flows produce undesirable effects during machining.
a) Divergent flow

Electrolyte flows from the inside of the tool. Then Around the cutting edges and up
through the machined hole. This method is simple, inexpensive.

b)Convergent flow

The electrolyte is admitted through a chamber pressurize the area outside the work
and tool. Through the valve fluid flow can be controlled.
 Figure 6: Electrolyte flow

Work piece:
A workpiece is an object that needs to be machined from which material goes into the
solution. The workpiece is made the anode in ECM. The material removal rate or
machining is only dependent upon the atomic weight and valency of the work material.

The workpiece can be any electrically conducting material and is insulated from the
system so that there is no leakage or short-circuiting of current.

Tool:
The tool is used to remove material from the workpiece. It is made the cathode and
connected to the negative terminal of the power supply. The tool is selected and
manufactured keeping in mind the following properties:

Good conductor of electricity.

Rigid enough to take up the load and fluid pressure.
Chemically inert with respect to the electrolyte.
Easily formable and machinable to the desired shape.
Should be manufactured with great accuracy
The cavity obtained in the workpiece is the replica of the tool shape. Therefore, the
accuracy of the workpiece after machining is directly affected by the accuracy of the tool
shape.

Available material for tool-making: Copper, Brass, Titanium, Copper-tungsten,

Stainless steel, Aluminium, Graphite, Bronze, Platinum, Tungsten Carbide.

Material is deposited in the tool in the ECM process. However, for the industrial purposes
of machining, the material deposition is discouraged and the material in solution is taken
away by the electrolytic solution.

The tool is insulated from the system so that there is no leakage or short-circuiting of
current.

Feed Unit:
The servo motor is used to provide the controlled feed to the tool for material removal
from the workpiece. Feed rate is 0.5 mm/min to 15 mm/min.
 Tank: It holds the electrolyte in which the tool and workpiece are immersed.
Workpiece holding table: The workpiece holding table holds the workpiece
firmly. Pressure gauge: This shows the pressure at which the electrolyte is supplied
to the tool.
Flowmeter: This shows the rate of flow of electrolyte to the machining area.
Flow control valve: Helps in controlling the rate of flow of electrolytes.
Pressure relief valve: The pressure relief valve opens and bypasses the
electrolyte to the tank in case the pressure rises in the supply lines.

Pump:
The pump helps in circulating the electrolyte. The rate of pumping and pressure at which
electrolytes will be pumped should be decided beforehand depending on the application
or requirement of the process.

Therefore, the pump for pumping electrolytes should be decided accordingly.

Reservoir tank: Stores the electrolyte.

Filters:
The filter helps in filtering the impurities present in the electrolyte which may choke the
supply lines.

Filters are used to realize precise ECM with high-cost effectiveness by maintaining the
electrolyte quality constant and removing residual toxic ions from the electrolyte for health
and environmental conservation purposes.

Sludge container: Stores the sludge produced during the machining.

Centrifuge: A centrifuge is a device that uses centrifugal force to separate the sludge
from the electrolyte.

Fume extractor: A fume extractor is a device that uses a fan with a negative draft to pull
fumes and dust out of the enclosure.

Enclosure: The entire system of ECM is put into an enclosure so that any toxic fumes
produced in the machining process do not affect the environment and operator.

Electrochemical Machining Working Principle:

Let us take an example of the machining of an iron workpiece. The iron workpiece is
assembled in the workpiece holding table.

The tool is brought close to the workpiece. The two electrodes immersed in the
electrolytic solution of NaCl (common salt solution).

The cathode (tool) and anode (iron workpiece) are connected to the negative and positive
terminal of the power supply (usually around 10 V) respectively.

The electrolyte from the reservoir tank is continuously pumped, streaming through the
hole in the tool, into the gap between the tool and the workpiece with the help of a
circulating pump.

The tool feed system advances the tool towards the workpiece.

Reactions at the anode are called anodic reactions. Reactions at the cathode are called
catholic reactions.

Basic reactions for sodium chloride electrolyte:

Disassociation of sodium chloride: NaCl ————→ Na+ + Cl–

Disassociation of water: H2O ————→ H+ + OH–

Cathodic Reactions: Hydrogen ions take away electrons from the cathode (tool) to form
H2 gas.

2H+ + 2e– ————→ H2↑

Only H2 gas is evolved at the cathode. The electrode shape remains unaltered during the
electrolysis process, which is the most significant feature of the ECM process.

Anodic Reactions:

Iron comes out of the workpiece (anode) as iron ions

Fe ————→ Fe++ + 2e–
Reaction within sodium chloride electrolyte

Na+ + OH–———→ NaOH

Fe++ + 2OH– ————→ Fe(OH)2 ↓

Fe++ + 2Cl– ————→ Fe(Cl)2 ↓

Fe(OH)2, Fe(Cl)2 are precipitated as sludge. The workpiece gets gradually machined to give
an excellent surface finish and stress-free surface because of this controlled anodic
dissolution process at the atomic level.

There are no constraints over the geometry of the tool shape. Initially, the gap between the
tool and workpiece is uneven. After the machining, the gap is uniform (0.1 mm to 2 mm)
throughout the length of the workpiece and maintained as such through the appropriate
tool or workpiece advancement rate.

The width of the gap gradually tends towards a steady-state value and under such
conditions, the cavity obtained is the replica of the tool shape.

The sludge from the tank is taken out and separated out from the electrolyte using the
centrifuge.

The electrolyte, after going through the filtration process in filters, again transported to the
reservoir tank to be pumped for the machining process.
PROCESS PARAMETERS OF ELECTRO CHEMICAL MACHINING

Current density - Current density is simply the current that can be passed into a square
inch of work area. At low current densities, metal removal rate is small. The relationship
between current density and metal removal rate as shown. The electrochemical machine
used for a particular application must have sufficient current available to maintain a
current density of 50-1500 A/in2.

Tool feed rate - Tool feed rate is directly proportional to current density. If the feed rate
is increased the electrical resistance of the tool-work gap reduces to allow current to flow
resulting in high metal removal rates. Also, it produces good surface finish and accuracy is
improved.

Gap between workpiece and tool - The tool and the workpiece are positioned as close
together to encourage efficient electrical transmission. Small gap results in high current
densities and hence, more metal removal. It is important to maintain a uniform gap
between the tool and the workpiece. Any physical contact between the tool and the
workpiece results in arcing and serious damage to both the members. The gap size may
vary from 0.25-0.76 mm. A gap size of 0.25 mm is often used.
Velocity of electrolyte flow - Electrolyte flow may be between 15-60 m/sec. If the
electrolyte flow is too low, the heat and by-products of electrolytic reaction (hydrogen gas
bubbles, sludge etc) build in gap of tool and workpiece causing non-uniform metal
removal. Too high velocity will cause cavitations, also promoting non-uniform metal
removal.

Type of electrolyte, its concentration and temperature -The type of electrolyte

selected depends on the tool and the workpiece material. For instance, sodium chloride is
cheap and provides good conductivity. However, it is corrosive and hence, cannot be used
on tungsten carbide or molybdenum materials. Sodium nitrate is also popular due to its
less corrosive nature. But it does not produce a good surface finish as that of sodium
chloride. Also, it is more expensive than sodium chloride. It is preferred for machining
aluminum and copper. The electrolyte in water at various concentrations affect the surface
finish produced. Low concentrations decrease the equilibrium machining gap resulting in
better surface finish and tolerance control. Electrolyte temperature seriously affects the
overcut. The power loss in electrolyte reaction gives rise to an increase in the temperature
of the electrolyte. The heat must be carried away from the cutting area so as to maintain
stable and steady conditions. Low temperature of electrolyte is conductive to better
surfaces finish and tolerance.

Electrochemical Machining Advantages:

The Following advantages of Electrochemical Machining is:

Complex and concave curvature parts can be produced easily using concave and
convex tools.
More complex geometries can be produced using a single connected CNC
 machine.
Since there is negligible tool wear, the same tool can be used for producing an
infinite number of components.
Since there is no direct contact between the tool and work material, there are no
forces and residual stresses.
An excellent surface finish is produced with no thermal damage due to atomic level
dissolution
Less heat is generated.

Electrochemical Machining Disadvantages:

The Following disadvantages of Electrochemical Machining is:

The saline(acidic) electrolyte can cause corrosion of the tool, workpiece, and
equipment.
High specific energy consumption.
ECM can machine only electrically conductive work material.
It can not be used for soft material.
A large production floor is required.
ECM poses health and environmental concerns.

Electrochemical Machining Application:

The Following application of Electrochemical Machining is:

1. Electrochemical Machining is used for Die sinking and hole-contouring operation.

2. Grinding, by combining with grinding processes (using the negatively charged
abrasive grinding wheel) to remove material. The process is also referred to as
electrochemical grinding.
3. Cutting cavities, drilling deeper and even irregular-shaped holes in complex
structures like jet engine turbine blades.
4. Trepanning (by using a tool electrode with a cavity) and micro-machining to
fabricate micro-components because ECM provides a stress-free and good surface
finish which has extensive application in Nanofabrication and nanotechnology.
5. Profiling and machining complex profiles like steam turbine blades within
closed limits.

.
 Electrochemical Grinding:

Electrochemical grinding is a variation of electrochemical machining.It was discovered

experimentally while working with ECM. However, some say that electrochemical grinding
became popular in the 1930s in the USA and was then used for grinding carbide in the
1950s.
Nowadays electrochemical grinding is a common process that has many advantages over
traditional grinding methods.

What is the Definition of Electrochemical Grinding?

The term grinding refers to a machining process in which the material is

removed from the surface of the workpiece. And the term electrochemical
resembles the mode of energy used for the machining process.
Electrochemical grinding is a combination of electrochemical machining and
grinding processes.

The major difference between ECM and ECG is that In ECG grinding wheel is used
instead of a cutting tool. Electrochemical grinding is done when there is a need to remove
the material from the surface of the workpiece. It is generally used when the mechanical
or traditional grinding of a workpiece takes a lot of effort due to the hardness of the
workpiece.

Hence it can be said that electrochemical machining is used for grinding materials with
greater hardness (greater than 65 HRC).

Electrochemical grinding is a reverse of electroplating. In this, the metal surface is

converted into its respective oxide which is then removed by the rotating grinding wheel.

Only 5-10% of the material is removed by the Abrasive grinding wheel, the rest is
removed by the flow of electrolyte.

Parts or Construction of Electrochemical Grinding:

The workpiece is kept on the worktable which acts as a rigid base. There are fixtures
located on the table to clamp the workpiece. Below the worktable, a collecting tank is
situated for the collection of waste electrolytes. The workpiece is connected to the
positive terminal of the power supply and acts as an anode while the grinding wheel acts
as the cathode. The power supply to the grinding wheel is given through the sleeve. The
supply line consists of an electrolyte tank. The pump is used to draw the electrolyte from
the tank which is followed by the filter, pressure gauge, and flow meter. The end of the
supply line is connected with a nozzle for increasing the pressure.

DC Power supply:
A DC power supply with low voltage and high current is used for providing electrical
energy to the setup. The voltage is kept low to avoid the generation of heat and for safety
purposes as well. High current on the other hand promotes a faster process.

Work Table and Fixture:

For any machining process, it is important to provide a rigid base and restrict all the
degrees of freedom of the workpiece. The worktable provides rigid support to the
workpiece and fixtures are used to clamp the workpiece.

Electrolyte tank:
An electrolyte tank is a reservoir in which the electrolyte is stored. An electrolyte is a
conducting solution that plays an important role in electrochemical grinding. The
first function of electrolyte is to complete the circuit by providing a conducting
medium.

The second function is to oxidize the metal surface and carry out the oxidized particles.
Electrolytes are generally Sodium compounds formed by electrovalent bonds. There are
various types of electrolytes used in electrochemical grinding such as Sodium nitrate
(generally used), carbonate, hydroxide, and Sodium chloride.

Pump:
A pump is used to carry the electrolyte from the electrolyte tank to the nozzle. The pump
used is generally electrically driven.

Filter:
The electrolyte passes through a filter where all the micro impurities get filtered and pure
Electrolyte is obtained.

Pressure Gauge and flow meter:

Pressure gauge and flow meter are safety equipment that shows pressure and flow of the
electrolyte respectively. If any of these values become more than the safety limit the
operator simply turns off the equipment.

Nozzle:
A nozzle is a device with decreasing cross-section area, which is used to direct the
electrolyte to the correct position. The decreasing area helps in increasing the velocity of
the electrolyte which in turn removes the material from the workpiece.

The nozzle is placed in such a way that the electrolyte flowing out of it must come in
contact with the workpiece as well as the grinding wheel.

Sleeve:
A sleeve is used to transfer electrical energy to the grinding wheel.

Grinding wheel:
The grinding wheel is the most important and unique part of the electrochemical grinding
machine. It is connected to the negative terminal of the power supply and acts as the
cathode.

The grinding wheel is made of insulating materials such as diamond and aluminum oxide.
The wheels rotate and increase the flow of the electrolyte.
The grinding wheel is responsible for only 5-10 % of the material the rest is removed by
the electrolyte. There is hardly any contact of the grinding wheel with the workpiece
hence no or very little wear takes place.

Collecting tank:
A collecting tank is used to collect all the used electrolyte which is then disposed or
reused as per the requirement.

Electrochemical grinding Working In detail:

Before understanding the working we must go through the principle of working of
electrochemical grinding.

The working principle of electrochemical grinding is When a metal surface is

acted upon with an electrolyte under a high current, the metal surface gets
oxidized to form an oxide layer (corrosive layer). This layer is removed with
the action of a flowing electrolyte and rotating grinding wheel. Metal is
removed in the form of an oxide layer to obtain an n surface finish.

The workpiece to be machined is first kept on the worktable and then clamped using
fixtures. The grinding wheel is placed at the required position. A gap is maintained between
the workpiece and the grinding wheel. This gap is generally 0.02mm.
Now the power supply is switched on. The pump is then driven to supply the electrolyte to
the required position. At first, the electrolyte passes through a filter where all the
impurities are filtered. Then the electrolyte is passed through a pressure gauge where the
operator checks for the correct pressure. Then electrolyte is passed through a flow meter
where flow is checked by the operator.
After passing through all the stages the electrolyte reaches the nozzle. Nozzle increases the
velocity of the electrolyte and sprays it over the workpiece. As soon as the electrolyte comes
in contact with the workpiece and the grinding wheel, the circuit is completed which results
in Oxidation of the metal surface. This forms a layer of oxide which is removed by the flow
of electrolyte and the Abrasive particles in the grinding wheel. After the grinding is done,
the flow is stopped and the power supply is switched off.

The workpiece is then unclamped and the remaining electrolyte is wiped out from the
surface.

Advantages of Electrochemical Grinding:

The following merits or advantages of Electrochemical Grinding are:

The accuracy of electrochemical grinding is very high. As there is no contact of the

tool with the workpiece.
A high tolerance can be obtained.
The process does not leave any scratches on the surface of the workpiece. The heat
generated during the operation is very less.
The electrolyte also acts as a coolant.
There are no internal stresses developed in the workpiece.
Hard materials can be grinded easily. Cleans
edges can be obtained.
No or very little wear of the grinding wheel takes place.
Disadvantages of Electrochemical Grinding:
The following demerits or disadvantages of Electrochemical Grinding are:

The metal removal rate is low, about 15mm/s

Power consumption is very high as there is a need to drive the grinding wheel and
pump as well.
The initial cost of the equipment is also high. The
production rate is low.
Disposing of waste electrolytes becomes a problem, which makes the process non-
eco-friendly.
A large area is required for setup.

Electrochemical Grinding:

Electrochemical grinding is a variation of electrochemical machining.It was discovered

experimentally while working with ECM. However, some say that electrochemical grinding
became popular in the 1930s in the USA and was then used for grinding carbide in the
1950s.Nowadays electrochemical grinding is a common process that has many advantages
over traditional grinding methods.

What is the Definition of Electrochemical Grinding?

The term grinding refers to a machining process in which the material is

removed from the surface of the workpiece. And the term electrochemical
resembles the mode of energy used for the machining process.
Electrochemical grinding is a combination of electrochemical machining and
grinding processes.
The major difference between ECM and ECG is that In ECG grinding wheel is used
instead of a cutting tool. Electrochemical grinding is done when there is a need to remove
the material from the surface of the workpiece. It is generally used when the mechanical
or traditional grinding of a workpiece takes a lot of effort due to the hardness of the
workpiece. Hence it can be said that electrochemical machining is used for grinding
materials with greater hardness (greater than 65 HRC).
Electrochemical grinding is a reverse of electroplating. In this, the metal surface is
converted into its respective oxide which is then removed by the rotating grinding wheel.
Only 5-10% of the material is removed by the Abrasive grinding wheel, the rest is
removed by the flow of electrolyte.

Parts or Construction of Electrochemical Grinding:

The workpiece is kept on the worktable which acts as a rigid base. There are fixtures
located on the table to clamp the workpiece. Below the worktable, a collecting tank is
situated for the collection of waste electrolytes. The workpiece is connected to the
positive terminal of the power supply and acts as an anode while the grinding wheel acts
as the cathode. The power supply to the grinding wheel is given through the sleeve. The
supply line consists of an electrolyte tank. The pump is used to draw the electrolyte from
the tank which is followed by the filter, pressure gauge, and flow meter. The end of the
supply line is connected with a nozzle for increasing the pressure.

DC Power supply:
A DC power supply with low voltage and high current is used for providing electrical
energy to the setup. The voltage is kept low to avoid the generation of heat and for safety
purposes as well. High current on the other hand promotes a faster process.

Work Table and Fixture:

For any machining process, it is important to provide a rigid base and restrict all the
degrees of freedom of the workpiece. The worktable provides rigid support to the
workpiece and fixtures are used to clamp the workpiece.

Electrolyte tank:
An electrolyte tank is a reservoir in which the electrolyte is stored. An electrolyte is a
conducting solution that plays an important role in electrochemical grinding. The
first function of electrolyte is to complete the circuit by providing a conducting
medium.

The second function is to oxidize the metal surface and carry out the oxidized particles.
Electrolytes are generally Sodium compounds formed by electrovalent bonds. There are
various types of electrolytes used in electrochemical grinding such as Sodium nitrate
(generally used), carbonate, hydroxide, and Sodium chloride.

Pump:
A pump is used to carry the electrolyte from the electrolyte tank to the nozzle. The pump
used is generally electrically driven.
Filter:
The electrolyte passes through a filter where all the micro impurities get filtered and pure
Electrolyte is obtained.

Pressure Gauge and flow meter:

Pressure gauge and flow meter are safety equipment that shows pressure and flow of the
electrolyte respectively. If any of these values become more than the safety limit the
operator simply turns off the equipment.

Nozzle:
A nozzle is a device with decreasing cross-section area, which is used to direct the
electrolyte to the correct position. The decreasing area helps in increasing the velocity of
the electrolyte which in turn removes the material from the workpiece.

The nozzle is placed in such a way that the electrolyte flowing out of it must come in
contact with the workpiece as well as the grinding wheel.

Sleeve:
A sleeve is used to transfer electrical energy to the grinding wheel.

Grinding wheel:
The grinding wheel is the most important and unique part of the electrochemical grinding
machine. It is connected to the negative terminal of the power supply and acts as the
cathode.

The grinding wheel is made of insulating materials such as diamond and aluminum oxide.
The wheels rotate and increase the flow of the electrolyte.
The grinding wheel is responsible for only 5-10 % of the material the rest is removed by
the electrolyte. There is hardly any contact of the grinding wheel with the workpiece
hence no or very little wear takes place.

Collecting tank:
A collecting tank is used to collect all the used electrolyte which is then disposed or
reused as per the requirement.

Electrochemical grinding Working In detail:

Before understanding the working we must go through the principle of working of
electrochemical grinding.

The working principle of electrochemical grinding is When a metal surface is

acted upon with an electrolyte under a high current, the metal surface gets
oxidized to form an oxide layer (corrosive layer). This layer is removed with
the action of a flowing electrolyte and rotating grinding wheel. Metal is
removed in the form of an oxide layer to obtain an n surface finish.

The workpiece to be machined is first kept on the worktable and then clamped using
fixtures. The grinding wheel is placed at the required position. A gap is maintained between
the workpiece and the grinding wheel. This gap is generally 0. 02mm.Now the power
supply is switched on. The pump is then driven to supply the electrolyte to the required
position. At first, the electrolyte passes through a filter where all the impurities are filtered.
Then the electrolyte is passed through a pressure gauge where the operator checks for the
correct pressure. Then electrolyte is passed through a flow meter where flow is checked by
the operator. After passing through all the stages the electrolyte reaches the nozzle. Nozzle
increases the velocity of the electrolyte and sprays it over the workpiece.

As soon as the electrolyte comes in contact with the workpiece and the grinding wheel,
the circuit is completed which results in Oxidation of the metal surface.This forms a
layer of oxide which is removed by the flow of electrolyte and the Abrasive particles in the
grinding wheel. After the grinding is done, the flow is stopped and the power supply is
switched off.The workpiece is then unclamped and the remaining electrolyte is wiped out
from the surface.

Advantages of Electrochemical Grinding:

The following merits or advantages of Electrochemical Grinding are:

The accuracy of electrochemical grinding is very high. As there is no contact of the

tool with the workpiece.
A high tolerance can be obtained.
The process does not leave any scratches on the surface of the workpiece. The heat
generated during the operation is very less.
The electrolyte also acts as a coolant.
There are no internal stresses developed in the workpiece.
Hard materials can be grinded easily. Cleans
edges can be obtained.
No or very little wear of the grinding wheel takes place.

Disadvantages of Electrochemical Grinding:

The following demerits or disadvantages of Electrochemical Grinding are:

The metal removal rate is low, about 15mm/s

Power consumption is very high as there is a need to drive the grinding wheel and
pump as well.
The initial cost of the equipment is also high. The
production rate is low.
Disposing of waste electrolytes becomes a problem, which makes the process non-
eco-friendly.
A large area is required for setup.
ELECTRO CHEMICAL HONING

Electrochemical honing is a modification of conventional honing. ECH is a process in

which the metal removal capabilities of ECM are combined with the accuracy
capabilities of honing. The process consists of a rotating and reciprocating tool inside
a cylindrical component. Material is removed through anodic dissolution and
mechanical abrasion – 8% or more, of the material removal occurs through
electrolytic action. As with conventional ECM, the workpiece is the anode and a
stainless-steel tool is the cathode.

Figure 8: Electro chemical honing tool

Tool consists of a hollow stainless-steel body that has expandable, nonconductive

honing stones protruding from at least three locations around the circumference. The
tool is rotated and reciprocated on a rigid spindle for precise metal removal from
internal cylindrical hole of the workpiece. The honing stones are identical with those
used in conventional honing operations, except that they must resist the
corrosiveness of the electrolyte. The honing stones are mounted on the tool body with
a spring-loaded mechanism so that each of the stones exerts equal pressure against
the workpiece. The length of the stones is selected to be approximately one-half the
length of the bore being processed.
At the beginning of the ECH cycle, the stones protrude only 0.075-0.127mm from the
stainless-steel body, establishing the gap through which the electrolyte flows. The
electrolyte enters the tool body via a sliding inlet sleeve from which it exits into the
tool-workpiece gap through small holes in the tool body. After passing through the
gap, the electrolyte flows from the workpiece through the gap at the top and bottom
of the bore. The mechanical action of the tool is the same as with conventional
honing; the tool is rotated and reciprocated so that the stones abrade the entire
length of the bore. Electrolytes used in ECH are essentially the same as those used in
ECM, although the control of pH, composition and sludge is less critical because the
abrasive action of the stones tends to correct any resulting surface irregularities. As
in ECM, the electrolytes are re-circulated and reused after passing through
appropriate filtration, and the most commonly used electrolytes are sodium chloride
and sodium nitrate.
 Figure 9: Electro chemical honing setup

Advantages

The most important advantage of this process is that we get both the surface
finishing and shaping as a result of this process. That means no need to spend your
time on the surface finishing and shaping separately. In case hard materials, the
tradition machining techniques are not applicable. But this is the perfect process for
the hard or tough materials. No heat is produced during this whole technique. It
gives you one of the best surface finishing. This method gives you the desired low
tolerance.

Disadvantages

More number of equipment’s are required during this process. The cost of machines
is too much high to carry out this process. Skilled labor is needed to implement this
metal removing process. It is only applicable to the hard materials mostly.

Applications

• Primarily used in the grinding of Tungsten carbide tool bits.

• Grinding of cutting tools, chilled iron castings, magnet alloys, contour milling
of honey- comb structures.
• Used for machining of cemented carbides, satellites, refractory materials,
stainless steel and high alloys steels without any burr.
• Chromium plated materials, flame hardened materials and temperature
sensitive alloys can be machined without forming thermal cracks and
distortion.
• Grinding of super alloy turbine blades.
• Burr free sharpening of hypodermic needles.