This document discusses various chemical and electro-chemical energy based machining processes. It introduces electro-chemical machining (ECM), electro-chemical grinding (ECG), electro-chemical honing (ECH), and electro-chemical deburring (ECD). These processes use a chemical solution and electric current to remove material from a workpiece through controlled chemical etching. ECM can machine complex shapes. ECG uses both chemical etching and abrasive grinding wheels to machine hard materials with high precision and without causing structural changes to the workpiece. Safety precautions must be followed when using acids in these electro-chemical processes.

1. UNIT -3
CHEMICAL AND ELECTRO-CHEMICAL
ENERGY BASED PROCESSES

2. CHEMICAL AND
ELECTRO-CHEMICAL
ENERGY BASED
PROCESSES

3. INTRODUCTION
• The metal is removed from the work piece
through controlled etching or chemical attack
of the work piece material in contact with a
chemical solution

4. Examples
1. Electro-chemical machining (ECM)
2. Electro-chemical Grinding (ECG)
3. Electro-chemical Honing (ECH)
4. Electro-chemical Deburring (ECD)

5. Chemical Machining

6. Processes in ECM
Maskant coating
Cleaning
Drying
Dipping in chemical solution
Stirring & Heating – For uptain Uniform Depth
washing

7. ETCHANT (CHEMICAL SOLUTION)

8. MASKANTS

9. • Scribed and Peeled Maskants
• Photo resists Maskants
METHODS OF MASKANTS

10. Maskant
.

11. .
.

12. Classifications of Chemical Machining

13. Advantages of CHM

14. Dis-advantages of CHM

15. .
Electro-chemical Machining (ECM)

16. .

17. ELECTRO-CHEMICAL GRINDING (ECG)
OR
ELECTROLYTIC GRINDING
.

18. Electro-chemical Grinding (ECG)

19. ADVANTAGES OF ECG
1. Life of the grinding wheel is high (because 90% material
removed by chemical process)
2. No heat is produced in the process so the work surfaces
are free from cracks.
3. Less cutting force only required
4. Good surface finish is obtained.
5. Work material not subjected to any structural changes
6. Burr free and stress free components are made.
7. No Frequent dressing of grinding wheel required.

20. DIS -ADVANTAGES OF ECG
1. High initial cost
2. Power consumption is high
3. MRR is lower than conventional method
4. Non – conducting material cannot be machined.
5. Need safety things for acid usage in process.
6. Maintenance cost is high

21. Applications of ECG
Its best suited for
1. precision grinding on hard materials
2. Cutting of hard material with thin sections
without any damage

22. ELECTRO-CHEMICAL HONING

23. Advantages of ECH

24. • More number of equipments used
• Cost of machine is high
• Required Skilled labours
• hard materials only machined.
Dis-advantages of ECH

25. ELECTRO-CHEMICAL DEBURRING