Electrochemical machining

(ECM)
Of high temperature titanium
alloy.
BY
DEBABRATA SAHU
REGD NO:-1721109146
PRODUCTION ENGINEERING
Contents:-
Introduction
Electrochemical machining
Working of ECM
Experimental setup
ECM of Ti60 blisk sectors
Process parameter of experiment
Results and discussion
Application
Advantages
Disadvantage
Conclusion
Reference
 Introduction:-
Electrochemical machining (ECM) is an electrochemical dissolution method to
produce smooth surfaces with a high accuracy and without limitations to the
mechanical properties of the alloys .
 ECM is increasingly being considered as an important method for the
production of hard-to-machine titanium alloys. Compared to traditional
technologies, ECM does not cause heat-affected zones and internal stresses on
the machining surface.
In addition, because ECM causes no tool wear and gives high material removal
rates, it is a very cost-effective and highly efficient production method.
 ECM for titanium alloys is titanium self-passivation , whereby a passive
oxide layer is formed, which inhibits the dissolution process.
Appropriate process parameters and a suitable electrolyte are important for the
machining.
This study focuses on the ECM of the high temperature titanium alloy Ti60.
 Electrochemical machining:-
Electrochemical machining (ECM) is a machining process in which
electrochemical process is used to remove materials from the work piece. In the
process, work piece is taken as anode and tool is taken as cathode.
The two electrodes work piece and tool is immersed in an electrolyte (such as
NaCl). When the voltage is applied across the two electrodes, the material removal
from the work piece starts.
The work piece 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
This process is used to machine only conductive materials.
ECM working is opposite to the electrochemical or galvanic coating or deposition
process.
During electrochemical machining process, the reactions take place at the
electrodes i.e. at the anode (workpiece) and cathode (tool) and within the
electrolyte.
 Working of ECM :-
First the work piece is assembled in the fixture and tool is brought close to the
work piece. The tool and work piece is immersed in a suitable electrolyte.
After that, potential difference is applied across the w/p (anode) and tool
(cathode). The removal of material starts. The material is removed as 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 is comes out as positive
ions and combine with the ions present in the electrolyte and precipitates as
sludge. Hydrogen gas is liberated at 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.
Materials:-
he work piece material is the Ti60 alloy,
which is made by a conventional
forging method in which the forging
temperature is below the phase
transition point (1050–1060°C).
Fig. shows the material morphology of
the Ti60 alloy. In the microstructure of
the conventionally forged Ti60, a major
part is occupied by lumpy equaled
primary α grains and the dendrites'
secondary platelet α phase and the
remaining β phase are intervened
(Fig 2-Microstructure of Ti60
between the α grains. material)
 Experimental setup:-
The structure and components of the samples used in the study were
characterized by using a metalloscope and by energy-dispersive X-ray spectroscopy
(EDX).
The metalloscope is a Zeiss Axioplan 2 Imaging & Axiophot 2 microscope. The
EDX investigations were performed using another microscope (JSM-6360LV,
JEOL, Japan).
Electrochemical measurements were performed using a three-electrode setup and
an electrochemical workstation (CHI660E, CH Instruments Inc., China).
the
working electrode was a Ti60 cuboids (10 × 10 × 5mm) whose five surfaces were
covered with resin and only one surface was exposed to pretreatment using wet
abrasive papers and rinsing with distilled water.
The
machining accuracy of the blade profile was measured using a coordinate
measuring machine (TESA Micro-Hite 3D, TESA, Switzerland).
(Fig 3-Single-feeding-axis (Fig 4-Custom-made blisk
ECM experimental system.) ECM machine tools)
 ECM of Ti60 blisk sectors:-
Ti60 blisk sectors using the custom-made blisk channel ECM machine tool and
profile ECM machine tool. ECM processing of blisk blade profiles often happens in
two steps.
 As shown in Fig. 5, the first step is channel ECM processing, which creates
several tens of curved tunnels with allowances.
The second step is blisk profile finishing ECM, which produces blades with good
machining accuracy and surface roughness

(Fig 5-Two steps of blisk ECM:(a) channel machining and (b)

blade profile machining.)
Fig. 6(c) shows the blisk sector sample after profile precision ECM. The
concave and convex profiles of the blade can be machined electrochemically
at the same time. For precision machining, the feeding rate of the cathode is
reduced to 0.5mm/min.

(Fig 6-(a) Ti60 work blank,

(b) sample after channel machining, and
(c) sample after blade profile machining.)
Process parameter of experiment:-
Item Value
Work piece material Ti60
Cathode material 1Cr18Ni9Ti
Electrolyte NaCl (10%)
Voltage 30 V
Inlet pressure 0.5 MPa
Temperature 40 ± 0.1°C
Initial gap 0 .5 mm
Feed rate 1.2 mm/min (for channel)
0.5mm/min (for profile)
Results and discussion:-
The current–voltage curves show that the
electrolyte composition as well as the
concentration influence the dissolution
behavior of the material.

Based on the measurements for sodium

chloride shown in Fig. 7, the curves can be
divided into two different regions. Between 0
and 2 V, the curves show a distinct area of
passivation.

There is no electrochemical dissolution, and

(Fig 7-Polarization curves for Ti60
currents are almost zero because the potentials alloy in sodium chloride with
are below the dissolution voltage (Ediss). different concentrations.)
When the potentials are more than2 V, the
currents increase gradually, which means that
electrochemical dissolution occurs.
 Application:-
The ECM process is used for die sinking operation, profiling
and contouring, drilling, grinding, trepanning and micro
machining.
It is used for machining steam turbine blades within closed
limits.
 Advantages:-
Negligible tool wear.
Complex and concave curvature parts can be produced easily by
the use of convex and concave tools.
No forces and residual stress are produced, because there is no
direct contact between tool and work piece.
Excellent surface finish is produced.
Less heat is generated.
 Disadvantage:-
The risk of corrosion for tool, w/p and equipment increases in the case of saline
and acidic electrolyte.
Electrochemical machining is capable of machining electrically conductive
materials only.
High power consumption.
High initial investment cost.
 Conclusion:-
This study focuses on the ECM of the high-temperature titanium alloy Ti60.

Because titanium exhibits the characteristic of self-passivation, choosing the

appropriate process parameters and a suitable electrolyte is important for
obtaining good machining results.

 The electrochemical dissolution behavior of Ti60 is analyzed. The anodic

polarization curves and the open circuit potential of Ti60 with sodium nitrate
and sodium chloride solutions are obtained.

the temperature of the electrolyte is under 30 °C.

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