Introduction

 Electrochemical Machining (ECM) is one of the newest and most useful

non-traditional machining (NTM) process belonging to Electrochemical
category.
 Electrochemical machining (ECM) is used to remove metal and alloys
which are difficult or impossible to machine by mechanical machining
process.
 Both external and internal geometries can be machined

 The reverse of electroplating means it removes metal instead of adding it.

 This machining process is based Michael Faraday’s classical laws of
electrolysis, requiring basically two electrodes, an electrolyte, a gap and a
source of D.C power of sufficient capacity.
Principle
 Faraday’s law of electrolysis :
The weight of the substance produced during
electrolysis process is directly proportional to
1.the current which passes
2.the length of time of
process
3.The equivalent weight of
the material
Two dissimilar metals are in contact with an
electrolyte and anode loses metal to cathode
•Anode : Workpiece
•Cathode : Tool
•Electrolyte : An electrically conductive fluid
Fig: Schematic illustration of electrochemical machining
Process
Working of ECM
 In the actual process of ECM, the cathode is tool
shaped(mirror image of work-piece) and anode is
the work-piece.
 A gap(0.05 to 0.7 mm) is provided between the tool
and work-piece and electrolyte flows through the
gap at a velocity of 30 to 60 m/s and it completes
the electrical circuit.
 Electrolyte is pumped at high pressure of 20
kgf/cm2(1.96 MPa) through the gap.
 Electrolyte must be circulated at a rate sufficiently
high to conduct current between them and to carry
heat.
 Metal is removed from the work-piece by dissolution
 The electric current is of the order of 50 to 40,000 A at 5
to 35 V D.C for current density of 20 to 300 A/cm2.
 Power of 3 KWh is needed to remove 16 cm3 of metal
which is almost 30 times the energy required in the
conventional process(when the material is readily
machinable).
Electrolysis process
 In the electrolytic circuit the electron is flow from
the work-piece through the power supply to the
tool.
 The electrolysis process that takes place at the
cathode liberates hydroxyl ions(OH-) and free
hydrogen.
 The hydroxyl ions combine with the metal ions of
the anode to form insoluble metal hydroxides and
material is thus removed from the anode.
 At cathode(tool),the following reactions takes place:
1. M++ e- M(M denotes metal)
2. 2H++ 2e- H2(Hydrogen evolution)
 At anode(workpiece), the following reactions takes
place with a halogen electrolyte:
1. M M++ e-(Metal dissolution)
2. 2H2O O2+ 4H++ 4e- (Oxygen evolution)
3. 2Cl- Cl2+ 2e- (Halogen gas evolution)
 As an example, in machining of iron in NaCl electrolyte, at
the cathode the reaction products are FeCl2, Fe(OH)2,
Fe(OH)3 which forms a layer and this is how iron is removed
by electrolytic action.
 Current of 1000 A would dissolve iron at the rate of about
15 g/min and generate hydrogen at a rate of about 300
cm3/min.
Process parameters
Elements of ECM
Important elements of ECM are:
1. Electrolyte
2. Tool (cathode)
3. Work-piece (anode)
4. D.C power supply

Electrolyte:
 Common electrolytes used are sodium chloride, sodium
nitrate, sodium hydroxide, sodium fluoride, sodium
chlorate, potassium chloride and sulphuric acid.
 These solution on reaction produce an insoluble
compound in the form of sludge.
 The main functions of an electrolyte in ECM are:
1. It carries the current between tool and work-piece.
2. It removes the products of machining and
other
insoluble products from the cutting region.
3. It dissipates heat produced in the operation.
 The essential characteristics of electrolyte includes:
1. Good electrical conductivity.
2. Non-toxicity and chemical stability.
3. Non-corrosive property.
4. Low viscosity and high specific heat.
 High velocity flow over the electrode surface is one of
the key factors of ECM. It is necessary to prevent
crowding of hydrogen gas and debris of machining.
 Tool (cathode):
 The most commonly used tool material are copper,
brass, titanium, copper tungsten and stainless steels
when electrolyte is made of salts of sodium and
potassium.
 Titanium has been found to be the most suitable tool
where the electrolyte has the tendency to anodize the
tool as in case of sulphuric acid.
 The other tool materials are aluminium, graphite,
bronze, platinum and tungsten carbide.
 The accuracy of tool shape directly affects the work-
piece accuracy.
 Electro-forming and cold forging are two methods of
tool shaping.
 The general requirements of tool material in ECM are:
1. It should be conductor of electricity.
2. It should be rigid enough to take up the load due
to fluid pressure.
3. It should be chemically inert to the electrolyte.
4. It should be easily machinable to make it in the
desired shape.

Work-piece (anode):
 Work-piece should be conductor of electricity. So it is
almost limited to metals only.