FABRICATION OF ELECTRO

CHEMICAL MACHINE

Guided by:Dr. V.K.Gorana Sir

Professor
Mech. Department

Presented by:1.
2.
3.
4.
5.
6.

Abhishek Shakya
12/486
Amar Kamboj 12/488
Pavan Kumar Garg 12/504
Rahul Sharma
12/508
Vimal Malav
12/517
Vijendra singh 12/518

CONTENTS
1.Objective
2.Introduction
3.Literature review
4.Work done so far
5.Work to be done
6.References

Objective
To understand the operating principle of electro chemical
process.
To understand the process parameters affecting the process.
This project consist fabrication of ECM machine which
perform various machining operation like deep hole drilling,
with the help of various tools and techniques of design of
production engineering.

INTRODUCTION
We are fabricating Electro chemical machine, which
is a advance machining method used to machine
hard, brittle, alloy metal.
In this machining method electrolyte is injected on
work piece at reasonable pressure up to 2 bar.

 In ECM machining process material is removed

by mechanism of anodic dissolution during an
electrolysis process.
We will use acid electrolyte solution and acidified
electrolyte solution to measure the surface finish
obtained by both solution.
Machining time at different voltages.

Parameter
Flow velocity of electrolyte
: 10-60 m/s
Inter electrode gap
: 1 mm
D.C. supply to tool and workpiece : 10-25 V
No. of tooth on worm gear
small gear
:5
large gear
: 40
Gear ratio for worm wheel : 1:8
Pitch of lead screw
: 2 mm
Length of lead screw
: 250 mm
No. of threads on lead screw : 125

LITERATURE REVIEW
S.No. Literature

Work

Result

Dr. V.K. Jain etal

(2003)

Electrochemical deep
hole drilling in super
alloy for turbine
application

At minimum tool
retraction, a uniform hole
profile with min DAROC
was obtained.

Dr. Dayanand S. Bilgi

etal (2006)

Hole quality and

interelectrode gap
dynamics during pulse
current electrochemical
deep hole drilling

DAROC varies
significantly with applied
voltage, bare tip length,
pulse on-time and duty
cycle. Tool feed rate has
moderate effect on
DAROC(Depth averaged
radial overcut).

Dr.K.P. Rajurkara
etal (2013)

Review of
Electrochemical
and Electro
discharge
Machining

Recent advancements in
various aspects of
electrochemical and
electro-discharge
machining that
reflect the state of the
art in these processes
are presented in this
paper.

Dr.Mohan Sen, H.S.

Shan (2004)

A review of
electrochemical
macro- to microhole drilling
processes

overview of EC
hole drilling processes,
their critical features,
range of their app. and
exp. & analytical
investigations of the
processes

A Study of Influence of
Dr.S.S.Uttarwar Electrochemical
Process
Dr. I. K. Parameters on the Material
Chopde
Removal Rate and Surface
Roughness of SS AISI

Andi Sudiarso etal Material Removal Rate on

ECM of Brass, Stainless
Steel, and Al using Brass
Electrodes

Parameter such as machining

voltage, feed, Current, Electrolyte
conc., electrolyte flow were
successfully controlled and were
allowed to vary according to need.
The different combinations of the
controlling factors were considered
for the experiment and to determine
their influence on MRR and SR of
SS304 work piece.

Mr. P. V. Jadhav Enhancement of surface

(2006)
finish of Electrochemically
(EC) drilled deep hole using
Rotating electrode.

Electrode diameter & conductivity

increases then surface roughness
value is decreased. Voltage, rpm,
federate remains constant..
Increase in pressure there is no effect
of surface roughness value.

Designed setup of ECM machine

WORK DONE SO FAR

1. Literature survey of various journals.
2. Visited IIT Kanpur to see already fabricated
ECM machine and got knowledge regarding
fabrication of ECM machine during 3-7
January 2016.
3. Parts used in fabrication of ECM machine
are purchased.
4. Designed the structure of ECM machine
5. Dimension of Tool

Stepper Motor Specifications

Torque

1 kg/cm

Voltage

6v

Current

0.4amp

Shaft diameter

6.33mm

Max. Rpm
Min. Rpm

140 rpm
1 rpm

Motor Case O.D.

56 mm

Stepper motor

Stepper Driver
Board name
Input voltage

Dual H bridge L298N

5-22 V

Stepper

Arduino Board specification (Arduino UNO R3)

Microcontroller

ATmega328P

Operating Voltage

5V

Input Voltage (recommended)

7-12V

Input Voltage (limit)

6-20V

Digital I/O Pins

14 (of which 6 provide PWM output)

PWM Digital I/O Pins

Analog Input Pins

DC Current per I/O Pin

20 mA

DC Current for 3.3V Pin

50 mA

Length

68.6 mm

Width

53.4 mm

Bill of material (Tentative):

Parts
Quantity
Approximate cost
Stepper motor
1
550/Stove
1
400/Metal work piece(steel) 1
50/Z axis Drive
1
2000/Steel Pipe 70cm
1
200/Arduino UNO R3 2
650*2 =1300
Stepper Driver
1
220/Jumper Wires
1 set
164/Adapter 12V
1
20/Box
1
500/-

Parts to be Purchased
Copper tube
Acrylic Sheet
Pressure regulator
Electrolyte solution

WORK TO BE DONE
1. Assembly of various parts
2. To measure the performance of ECM machine at various
voltage and electrolyte solution
3. To determine the machining time at different voltage
4. To drill hole of diameter 1mm with the help of copper
tube as tool

DC Motors
Fast, continuous rotation motors
Used for anything that needs to spin at a high RPM e.g. car
wheels, fans etc.
Servo Motors
Fast, high torque, accurate rotation within a limited angle .
Generally a high performance alternative to stepper motors, but
more complicated setup with PWM tuning. Suited for robotic
arms/legs or rudder control etc.
Stepper Motors
Slow, precise rotation, easy set up & control
Advantage over servo motors in positional control. Where servos
require a feedback mechanism and support circuitry to drive
positioning, a stepper motor has positional control via its nature of
rotation by fractional increments. Suited for 3D printers and
similar devices where position is fundamental.

REFERENCES
Rajurkar K.P. , Sundaram M.M ,Malshe A.P.(2013) Review of electrochemical
and electro discharge machining Procedia CIRP 6(2013) 13-26
Bilgi Dayanand S., Jain V.K. , Shekhar
R. , Mehrotra Shaifali (2004)
Electrochemical deep hole drilling in super alloy for turbine application Journal of
Materials Processing Technology 149 (2004) 445452
Sen Mohan, Shan H.S (2004) A review of electrochemical macro- to micro-hole
drilling processes International Journal of Machine Tools & Manufacture 45 (2005)
137152
Bilgi Dayanand S., V. K. Jain, Shekhar R., Kulkarni Anjali V. Hole quality and
interelectrode gap dynamics during pulse current electrochemical deep hole drilling
Int J Adv Manuf Technol DOI 10.1007/s00170-006-0572-9

 Mr. P. V. Jadhav Enhancement of surface finish of Electrochemically (EC)

drilled deep hole using Rotating electrode. (net source)
S. S. Uttarwar and I. K. Chopde Experimental Study of Effect of Parameter
variations on output parameters for Electrochemical Machining of SS AISI
202 IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN:
2278-1684 Volume 5, Issue 5 (Mar. - Apr. 2013), PP 65-71
www.iosrjournals.org www.iosrjournals.org 65
Non conventional machine module 5 by IIT Mumbai
Electrochemical Drilling of Inconel Super alloy with Acidified Sodium
Chloride Electrolyte - Springer_files

THANK YOU