Presentation on the working and parameters affecting the efficiency of the machine

1. MICRO ELECTROCHEMICAL
MACHINING PROCESS AND PROCESS
PARAMETERS
Under the guidance of Dr. P.Mukhopadhyay
NAME UNIVERSITY ROLL NUMBER
SK ARBAJ ALI 10300717049
SK SUJAN ALI 10300717047
SALMAN HAIDER 10300717066
MD AHSAAN ALAM 10300717108
RAJEEV RANJAN 10300717079
SK JAFAR HOSSAIN 10300717048

2. Contents
 Introduction
 Overview
 Importance of MicroECM
 Applications
 Electrochemistry of MicroECM
 MicroECM working
 Characteristic
 Parameters
 Advantages and Disadvantages
 Parts
 Design
 Conclusion

3. INTRODUCTION
 µECM is a non-conventional machining (NCM) process
which is based on anodic dissolution of materials at
atomic level and it is suitable for conductive materials.
µECM has based on similar foundation as ECM but it is a
younger technology and it has been used for micro and
nano dimensions products and recently has attracted
more attention at the academic and industrial research
and development levels. This process is referred to as
ECM and PECM (Precise Electro-Chemical Machining),
PECM (Pulse Electro-Chemical Machining) at macro
level and is referred as µECM, µPECM (Micro Pulse
Electro-Chemical Machining), EMM (Electrochemical

4. OVERVIEW
ECM plays an important role in
manufacturing of a variety of parts
ranging from machining of complicated
shape, complex, and large metallic
pieces.
• ECM, ELECTROPLATING, ELECTROPOLISHING based on the
concept of Faraday’s law.
FARADAY’S
• ECM is based on electrolysis process where material is removed
from workpiece surface atom by atom.
ECM
• INPUT PARAMETERS: Supplied voltage, Machining current,
Electrolyte type, Concentration, Flow, and Inter-Electrode gap
• OUTPUT PARAMETERS: Metal removal rate, surface finish, and
profile accuracy.
PARAMETERS

5. IMPORTANCE OF MICRO
ECM
• is the need of time
• Medicals, micro tools, Mobiles, Mini Robots, Bio-Medical
implants , utensils, etc.
MINIATURISATIO
N
• Consists the application of various ultra precision processes
applied to make micro-sized holes, slots and micro complex
surfaces that are needed in large numbers.
ADVANCED
MICRO-MACHINING
• High tool wears, lack of rigidity of process and heat
generation at the tool - workpiece interface.
• It is troublesome to machine 3 dimensions micro shapes.
LIMITAIONS OF
TRADITIONAL
MACHINING
Most non-traditional micromachining processes are thermal oriented, e.g.
electro-discharge machining (EDM), laser beam machining (LBM) and
electron beam machining (EBM), which may cause thermal distortion of the
machined part. Chemical machining and ECM are thermal-free processes, but
chemical machining cannot be applied to machine chemically resistant
materials

6. ELECTROCHEMISTRY OF
MICRO ECM
The anodic work piece in ECMM is dissolved according to Faraday’s laws of
electrolysis. The dissolved material and other by-products generated in the
process such as sludge and cathode gas, are transported out from the gap by
the flowing electrolyte.
Methodology:
• DC voltage is applied between work piece (anode) and tool (cathode)
• Many electrochemical reactions occur at the cathode, the anode and in
electrolyte.
Factors influencing the oxidation potential:
• Nature of metal being machined
• Type of electrolyte
• Current density
• Temperature of electrolyte

7. MICRO ECM WORKING
 ECM - anodic dissolution process
 workpiece and tool are respectively
anode and cathode,
 Separated by electrolyte.
 Gap between anode and cathode: IEG
(inter electrode gap)
• ECM is often characterized as "reverse
electroplating," in that it removes material
instead of adding it.
• ECM: The anode workpiece dissolves
locally so that the shape generated is
approximately negative mirror image of tool
ELECTROPLATING

8. CHARACTERESTICS AND
PROCESS PARAMETERS OF
MICRO ECM
µECM follows the same approach as ECM; it is based on the same fundamental principles, but its
structure is adapted for micro and nano scale products with the dimensions in the range of 5 to
500 µm. The Table below compares the general setup and features between ECM and µECM.

9. MAJOR FACTORS AND
PARAMETERS OF MICRO ECM
A. Inter – Electrode Gap
• it is important to keep the IEG as small as possible
• IEG should be sustained between 5 and 50 µm
• Any minor change in this factors or their causes can have enormous effects on the machining
productivity
• It accelerates the electrolyte-heating rate and will increase its temperature;
• The final impact is the increased current density, which is supposed to improve localization
and machining process performance.
B. Tool Feed Rate
• The tool feed rate along the path of the tool electrode is defined as the speed of the tool
electrode during the process
• The aim of the µECM is to machine in the order of micrometres; hence, it requires the tool
movement to be in micro-orders and as low and precise as possible.
• It is important to maintain the tool feed rate in synchronization with the material removal rate
(known as equilibrium speed) to maintain the gap size.

10. ADVANTAGES AND
DISADVANTAGES
a. There is no residual
stress
b. Versatility to
machine any kind of
material
c. There is no problem
of heat affected zone.
d. There is no tol wear.
e. Short machining
time
f. Cost effective
g. High precision can
be achieved.
h. Excellent surface
finish.
ADVANTAGES
a. The risk of corrosion
of tool, workpiece and
equipment increases in
case of saline and
acidic electrolyte.
b. It is capable of
machining electrically
conductive material
only.
c. High power
consumption .
d. High initial
investment.
DISADVANTAGES

11. Parts Of micro ECM and
significance
 Fixture
 Table
 Workpiece
 Tool
 Electrolyte
 Pump
 Filter
 Pressure gauge
 Flowmeter
 Feed unit
 Power supply

12. Fixture
The Fixture is used to hold the table firmly.
Table:
The table is used to hold the work piece properly.
Workpiece:
It is the material on which machining is carried out to remove the material from
the surface of the workpiece. Here, the workpiece acts as an anode.
Tool:
With the help of the tool, material removal takes place in the workpiece. Here,
the tool acts as a cathode.
Electrolyte:
The electrolyte acts as a medium for the flow of ions and leads to the removal
of material from the surface of workpiece.
Pump:
It pumps the electrolyte from the sump to all the parts of the system.
Filter:
It removes the impurities present in the electrolyte which is being pumped to the
system or work region.

13. Pressure gauge:
It is used to check the pressure of the electrolyte coming from the pump via a
filter to the work region.
Flow meter:
It is used to measure the discharge or mass flow rate of the fluid(electrolyte).
Feed Unit:
To give the feed to the tool, servomotor is used such that whenever material
removal takes place from the workpiece, the servomotor gives the necessary
amount of feed to the tool.
Power Supply:
The power supply is to be given to the machine to work properly. Here +ve
supply is given to the workpiece(acts as an anode) and the -ve supply is given
to the tool(acts as a cathode).
This is the explanation for the parts of Electrochemical Machining. Let's
understand the working principle of it.

15. Input from
computer
Work Piece
Insulating
Base
Z axis
mover
Electrod
e
Motor
Electrode
X-Y Plane Mover
Tool

16. Side Mounts Side
Mounts
Base
X and Y Plane VIew

17. APPLICATION OF MICRO
ECM
ECM has been successfully used in cutting, deburring, drilling industries and
shaping workpiece; it has been applied in many industrial applications
including turbine blades, engine castings, bearing cages, gears, dies and
molds and surgical implants.
The success of the ECM process has motivated the researchers and
technology developers to adjust and apply the process in micro and nano
production.
µECM has been successfully tested for different industrial applications
including but not limited to the following examples (Ivanov and Mortazavi,
2016):
• Drilling holes in the fuel injector nozzles
• Drilling cooling holes for turbine blades
• 3D sharpening of medical needles

18.  Here, wide scope of possibility and improvement is
required.
 Improvement of the control system, improvement of
the tool clamping system.
 Improvement of the workpiece clamping system, work
on the pulse PSU to reduce the noise generated by
the power semiconductors during the turn-on and
turn-off times
 Development of a machine learning algorithm and
comparison of performance with the already existing
control strategy. All this correctness is to increase the
accuracy and precision by controlling the outer factor
like vibration, short circuit etc.
FUTURE SCOPE

19. CONCLUSION
To obtain the best optimized values of machining features
and to develop the micro-ECM experimental set-up was
fairly do-able however the analysis part required higher
level of design expertise which was difficult to achieve at
that moment.
All through our project has been great experience and
with the CAD design we did the working and machining
process became fairly easy to understand.

20. 