Electrochemical machining (ECM) is a non-traditional machining process that removes metal through an electrochemical process rather than traditional cutting or grinding. In ECM, a power supply creates a voltage between the workpiece (anode) and tool (cathode) through an electrolyte, causing metal ions from the workpiece to dissolve and flow to the tool. This allows for complex internal and external geometries to be machined in hard metals. ECM is well-suited for mass production of parts with intricate shapes and difficult-to-machine materials due to its ability to machine stress-free and with high precision and surface finish.

1. ELECTROCHEMICAL MACHINING

2. Schematic illustration of the electrochemical machining process.

3. PARTS MADE
(a) Turbine blade made of nickel
alloy of 360 HB. Note the
shape of the electrode on the
right.
(b) Thin slots on a 4340-steel
roller-bearing cage.
(c) Integral airfoils on a
compressor disk.

4. 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.

5. PRINCIPLE
 Faraday’s law of electrolysis : The Weight of the substance produced during electrolysis
process is directly proportional to:
 Current which passes
 Length of time of process.
 The equivalent weight of the material
 Two dissimilar metals are in contact with an electrolyte and anode loses metal to cathode.

6. PARTS
 ANODE : Workpiece
 CATHODE : Tool
 ELECTROLYTE : An electrically conductive fluid

7. PARAMETERS

8. PARAMETERS

9. PROCESS

10. 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

11. 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..

12. 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 & Stainless steel.
 OUTER INSULATION MATERIAL :
Vinyl, Teflon, epoxy, enables or high temperature varnish.

13. CONTROL SYSTEM
 Control Parameters include:
• Voltage
• Inlet and outlet pressure of electrolyte
• Temperature of electrolyte
 The current is dependent on above parameters and feed rat .

14. ADVANTAGES
 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

15. DISADVANTAGES
 Initial tooling can be timely and costly
 Environmentally harmful by-products
 Complicated tool design
 Large power consumption

16. CHARACTERISTICS
 Stress free grooves
 Any groove geometry
 Any conductive metal can be machined
 Repeatable accuracy of 0.0005”
 High surface finish
 Fast cycle time.
 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.