MGM’s College of Engineering & Technology, Noida

Project Presentation 6
on
“FABRICATION OF ECM”

Under the supervision of: Submitted by:

Mr. Abhijit Kulkarni Sunil Kumar(1509540063)
(Assistant Professor) Akash Pal(1509540005)
Anupam kr. Singh(1509540014)
Md. Ashif(1409540035)
 Content
 Introduction  Fabricated parts of ECM

 Literature Review  Work done so far

 Objective & Motivation  Future works

 Setup of ECM  References

 Process Parameters

 Pump and transformer

 Methodology used
 Introduction
 Electrochemical Machining (ECM) is a non-
traditional machining process, Which is opposite of
electrochemical or galvanic coating.

 Working Principle:-

ECM works on the principle of Faraday law of

electrolysis in which ions are displaced from work
piece.
 Literature Review
Sr.No Author Input Output Conclusion
.
1 A. Mohanty, concentration of MRR The MRR
Gangadharudu electrolyte, increased with
Talla, voltage, feed increase in
S. Dewangan rate, electrode voltage
(2014) gap

2 Tingyu Xue Work piece Surface The cathode

(2016) material Tool Roughness feed rate could
material be increased to
Electrolyte improve
surface
roughness.
Objectives:-
Fabrication of ECM machine.

Analysis of variation of output on different

input parameters.

Motivation:-
Curiosity to know the detail working of ECM.

Machining at low power input.

Setup of ECM
 Process Parameters
Sr. Input Output
No.
Parameter Parameter
1 Tool gap Small
Medium
Large

2 Electrolyte Molarity bases MRR,

concentration Surface finish
3 Electrode Copper, brass,
material bronze
4 Electrolyte type NaCl, KOH,
NaNo3
 Pump Transformer
Working principle is INPUT
centrifugal type. Frequency = 50 Hz
Power consume = 0.035 kw Voltage = 220 volt
Voltage = 220 Volt. Current = 1.67 amp.
Total head = 1.5 meter. (alternate current)
Material of the pump is OUTPUT
Teflon (C2F4)n . Voltage = 24 volt
Flow rate through the pump Current = 25 amp.
= 1800 LPM. (direct current)
 Methodology Used

Literature Assembly of
Experimentation
review parts

Fabrication &
Testing &
Market survey Purchase of validation
parts

Conceptual Optimization &

Selection of
design &
material documentation
drawing
Fabricated Parts of ECM Machine
Stand Structure
Fabrication of Table
Electrolyte tank Machining Tank
Tool Holder
Complete Structure
 Work Done After 4th Presentation
Drilling and filing in tank
Tap fitting
Salt measuring
Electrolyte Solution prepared
Wiring of ECM machine
Discharge measuring through pipe
Electrode grooving & facing
Testing of ECM
Complete Assembly of ECM
 Molarity Concentration
NaCl solution
Molecular weight = 23+35
= 58 g/mol
Weight of the salt = 250 g
Volume of solution = 15 liters
No. of moles = weight/ molecular weight
= 250/58 = 4.3 mole
Molarity conc. = No. of moles/ volume
= 4.3/15 = 0.286
Circuit Diagram of ECM
 Pump Actual Discharge
Pump discharge has been measured on 15 liters
of water.
Volume of liquid = 15 liters
Time taken to pump water from electrolyte tank
to machining tank = 40 second
Discharge = (vol. of liquid pump) ÷ (time taken)
= 15 ÷ 40
= 0.375 liter/sec
= 0.000375 cubic meter per sec.
Work-piece before Work-piece after
machining machining
Work-piece after machining
 Work done so Far
 Complete ECM Setup
 Testing
 Salt Concentration
ECM Setup
 Test on Al by copper tool

Copper Tool Al Sheet

Machining
 Test on Al by brass tool

Brass tool Al Sheet

 Salt Concentration
NaCl solution
Molecular weight = 23+35
= 58 g/mol
Weight of the salt = 300 g
Volume of solution = 18 liters
No. of moles = weight/ molecular weight
= 300/58 = 5.17 mole
Molarity conc. = No. of moles/ volume
= 5.17/18 = 0.287
Test on GI sheet by brass tool

Brass Tool GI Sheet

Test on GI sheet by copper tool

Copper Tool GI Sheet

Test on GI sheet by copper tool

Copper Tool GI Sheet

Test on GI sheet by hollow copper tool

Hollow Copper Tool GI Sheet

 Salt Concentration
NaCl solution
Molecular weight = 23+35
= 58 g/mol
Weight of the salt = 250 g
Volume of solution = 15 liters
No. of moles = weight/ molecular weight
= 250/58 = 4.3 mole
Molarity conc. = No. of moles/ volume
= 4.3/15 = 0.286
 Future Work
Testing and validation.
 References
[1] Mohan Kumar, (2016) Electrochemical
Machining: Review Of Historical And Recent
Development,vol no. 5 issue no. 03.
[2] K.P. Rajurkar, M.M. Sundaram, (march
2013) Review of Electrochemical The
Seventeenth CIRP Conference on Electro-
Physical and Chemical Machining(ISEM).
[3] Adam Ruszaj (2014) A sequential
electrochemical-electro discharge process for
micro part manufacturing, Precision
Engineering, 38, 680–690.
Thank you