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ECM : Electrochemical machining - Principle,process,subsystems & applications

ECM : Electrochemical machining - Principle,process,subsystems & applications. Specialized processes under ECM.

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ECM : Electrochemical machining - Principle,process,subsystems & applications

  1. 1. Pratik Chaudhari TY mech MIS- 111210015 Subject – AMT
  2. 2. Introduction  Non-conventional machining system in which metal is removed by electrochemical process  Characterized as ‘Reverse Electroplating’ means it removes metal instead of adding it  Normally used for mass production and for hard materials that are difficult to machine using conventional processes  Both external and internal geometries can be machined
  3. 3. 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
  4. 4. •Anode : Workpiece •Cathode : Tool •Electrolyte : An electrically conductive fluid
  5. 5. Process parameters
  6. 6. Process
  7. 7. Main subsytem  Power Supply  Electrolyte  Tool  The Control system  The machine
  8. 8. Power Supply  Available in sizes upto 10,000 amp (some circuits are available upto 40,000amp)  Range of voltage – 2 to 30 volts d.c.  A constant voltage has to be maintained and high density is required
  9. 9. Electrolyte  Essential for electrolytic process  It cools the cutting zone which becomes hot due to the flow of high current  Neutral salts are used as electrolyte in place of highly corrosive acids and alkalies  Electrolyte solution is pumped between the tool/workpiece gap at about 2.5 N/mm2 and 30 m/s
  10. 10. Tool  Requirements of Tool For ECM :  Good thermal conductivity  Strong enough to withstand high pressures  It should be easily machined •Material for tool : Copper,brass or stainless steel •Outer insulation material : Vinyl, Teflon, epoxy, enables or high temperature varnish
  11. 11. The control system  Control Parameters include  Voltage  Inlet and outlet pressure of electrolyte  Temperature of electrolyte •The current is dependent on above parameters and feed rate
  12. 12. Specialized ECM…
  13. 13. STEM Figure The shaped-tube electrolytic machining (STEM) cell process is a specialized ECM technique for drilling small holes using a metal tube electrode or metal tube electrode with dielectric coating.
  14. 14. Electrochemical Micro-machining •Improves resolution of anodic dissolution from millimetres to micrometres •Micromachining applies pulses in nanoseconds instead of direct currents
  15. 15. Ref – L.cagnon,V.lircher,M.cock,R.schuster,G.Ertlth.Gmelin and H.kueck, Z. Phys chem . 217, (2003), 299-313
  16. 16. Further specialized Applications  Die Sinking  Profiling and contouring  Trepanning  Grinding  Drilling  Micro-machining  Pulsed ECM
  17. 17. Economics & Products  The process is economical when a large no. of complex identical products are to be made  Large cavities are more economical on ECM and can be made in 1/10th time in EDM  Two most common products :  Turbine/compressor blades  Rifle barrels Important characteristics that can be achieved are : •Stress free grooves •Any groove geometry •Any conductive metal can be machined •Repeatable accuracy of 0.0005” •High surface finish •Fast cycle time
  18. 18.  ECM is well suited for the machining of complex two-dimensional shapes  Delicate parts may be made  Difficult-to machine geometries  Poorly machinable materials may be processed  Little or no tool wear  Initial tooling can be timely and costly  Environmentally harmful by-products  Complicated tool design  Large power consumption Advantages Disadvantages
  19. 19. References  Electrochemical machining – nptel  Science Direct – ECM  Wikipedia – electrochemical machining  Wendt – electrochemical machining & miccromaching
  20. 20. Thank You …

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ECM : Electrochemical machining - Principle,process,subsystems & applications. Specialized processes under ECM.

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