Definition, Principle, Equipment, Working, Advantages, Disadvantages, Applications

1. Electro
Chemical
Machining
Definition, Principle, Working, Advantages, Disadvantages,
Applications

2. What is Electron beam?
• The Electron Beam is a stream of negatively charged
particles that are generated, accelerated, and some
extent, focused inside a device called an ” Electron
Gun”.

3. Electrochemical Machining Definition
• It is the method of removing metal from the electrochemical
process, where DC current is passed between the
tool(cathode) and workpiece(Anode) through an electrolyte
is known as ECM machining.
• In this process, a combination of electrical energy and chemical energy
is used to remove materials from the workpiece.

4. Principle-
Here is the principle of Electrochemical machining-
• Electrochemical machining works based on
Faraday’s laws of electrolysis.
• The amount of metal removed by machining or deposited is
calculated from faraday’s laws of electrolysis.
• For more information- Electrochemical Machining

5. Construction of Electrochemical Machining-
• There are several electrochemical machining equipment used to construct
the electrochemical machine in the electrochemical machining process-
• Dc power supply
• Table
• Workpiece
• Tool
• Feed Unit
• Electrolyte
• Pump
• Filter
• Pressure gauge
• Flow Meter
Read in-depth about its construction - Electrochemical Machining

6. Working of Electrochemical Machining
• The electrolyte is supplied to the system of anode and cathode, ie, workpiece and tool
using the pump.
• In between the pump and the system a filter is placed which is used to filter the
electrolyte before reaching the system.
• After passing through the filter and flow regulator, the electrolyte reaches the space
between the workpiece and the tool.
• As the electrolyte reaches the gap between anode and cathode, electrical contact is
established between the anode and the cathode.
• After the electrical contact is established, the positive ions start flowing from the
workpiece towards the tool and negative ions start flowing from the tool towards the
workpiece.
• When the positive ions flow from the workpiece towards the tool, the electrolyte carries
away the positive ions with it and stops it from reaching the tool.
• So the materials start removing from the workpiece as positive from the workpiece are
dissolve and carried away by electrolyte and materials are also removed due to the
striking power of the negative ions coming from the tool.
• Read in-depth about its working - Electrochemical Machining

7. Fig.- Diagram of laser beam machining

8. Advantages of Plasma arc machining
Here are some advantages of the ECM machining
process-
• It can cut any materials irrespective of their hardness, strength or toughness.
• Complex cavities can be produced using ECM machining.
• Tool wear is zero as there is no direct contact between the tool and the
workpiece.
• A very good surface finish is produced in this process as the material removal
takes place due to atomic level dissociation.
• Very little heat is generated during this process.
• No residual stresses as there is no direct contact between the tool and the
workpiece.
• There is no thermal damage to the workpiece.

9. Disadvantages of plasma arc machining
Here are some disadvantages of ECM, given
below-
• Only electricity conductive material can be machined.
• It can not be used for machining soft materials and non-
metals.
• The original problem of poor dimensional accuracy
• Environmentally polluting large waste
• The acidic electrolyte poses the risk of corrosion to tools,
workpieces and equipment.
• Read remaining points of disadvantages of Electrochemical Machining

10. Applications of Electron jet machining-
• Sinking operations
• Drilling
• Trepanning
• Profile and contouring
• Micro-machining

11. Here are some more machining processes, You would like to
read-
• laser beam machining
• Plasma arc machining
• Electric discharge machining
• Electrochemical Machining
• Water Jet Machining
• Abrasive Jet Machining
• Ultrasonic Machining
• Difference Between Conventional and Non-
Conventional Machining Processes

12. That’s It for now
Thank you for watching
For moreinformation visit- www.engineersrail.com