What are the various process characteristics of the ECM?

Different from the other machining processes, in ECM there is no contact between tool and work-piece. The main components of ECM system are a low voltage and high current power supply and an electrolyte. The electrolyte is normally solutions of inorganic salts, like sodium chloride (NaCl) or sodium nitrate (NaNO3).

What are the advantages of electrochemical machining?

High metal removal rates are possible with ECM, with no thermal or mechanical stresses being transferred to the part, and mirror surface finishes can be achieved. In the ECM process, a cathode (tool) is advanced into an anode (workpiece).

What is the principle of electrochemical machining?

THE ELECTROCHEMICAL PROCESS

In electrochemical machining, positive ions move towards the tool, and negative ions move towards the workpiece. This is the opposite of electroplating. As electrons cross the gap between the workpiece and the tool, metal ions come away from the workpiece.

What are the applications of electrochemical machining?

ECM is used to machine work pieces from metal and metal alloys irrespective of their hardness, strength or thermal properties, through the anodic dissolution, in aerospace, automotive, construction, medical equipment, micro-systems and power supply industries.

What is the advantages and disadvantages of electrochemical machining?

Advantages and disadvantages of electrochemical machining

The rate of machining does not depend on the hardness of the work piece material. The tool does not wear. Soft materials (e.g., copper) may be used for tool fabrication. No stresses are produced on the work piece surface.

What are the limitations of EDM?

Disadvantages of Electrical Discharge Machining

The slow rate of material removal. The additional time and cost used for creating electrodes for Ram/Sink EDM. Reproducing sharp corners on the work piece is difficult due to electrode wear.

What are the major application of ECM?

Application. The ECM process is used for die sinking operation, profiling and contouring, drilling, grinding, trepanning and micro machining. It is used for machining steam turbine blades within closed limits.

What are the differences between ECM & EDM?

Both EDM and ECM are non-conventional machining methods; however, both processes have considerable differences. EDM, or electrical discharge machining, relies on localized spark erosion to remove material, whereas ECM, or electrochemical machining, utilizes electrolysis to dissolve the metal locally.

What are the advantages and disadvantages of laser beam machining?

Advantages and Disadvantages:

It produces finish part or high surface finish. No tool wear because no physical tool is used. Micro holes can be drilled accurately. Complex shape can be machined easily because laser can be move in any path.

What are the major application of ECM?

Application. The ECM process is used for die sinking operation, profiling and contouring, drilling, grinding, trepanning and micro machining. It is used for machining steam turbine blades within closed limits.

What are the applications of electrochemical grinding process?

Applications. Electrochemical grinding is often used for hard materials where conventional machining is difficult and time-consuming, such as stainless steel and some exotic metals. For materials with hardness greater than 65 HRC, ECG can have a material removal rate 10 times that of conventional machining.

What is the difference between ECM and EDM?

Both EDM and ECM are non-conventional machining methods; however, both processes have considerable differences. EDM, or electrical discharge machining, relies on localized spark erosion to remove material, whereas ECM, or electrochemical machining, utilizes electrolysis to dissolve the metal locally.

What are the electrolyte used in ECM?

The most common electrolyte used for ECM is a concentrated salt electrolyte, namely, sodium chloride or sodium nitrate.

Which type of energy is used in electro chemical machining?

The noteworthy feature of electrolysis is that electrical energy is used to produce a chemical reaction, therefore, the machining process based on this principle is known as Electrochemical machining (ECM).

How is material removed in electrochemical machining?

In electrochemical machining, the metal is removed due to electrochemical action where the workpiece is made anode and the tool is made the cathode. A high current is passed between the tool and workpiece through the electrolyte. Metal is removed by the anodic dissolution and is carried away by the electrolyte.

What are the two main criteria for selecting the electrolyte in ECM?

What Should be The Criteria of Selecting Electrolyte in Electrochemical Machining (ECM) and Grinding (ECG)
  • · Required Machining rate.
  • · Required Dimensional Accuracy.
  • · Surface Texture and Integrity.

What are the basic requirements of tool material for ECM process?

The major requirements for a material to be used as a tool in ECM are high electrical and thermal conductivity, corrosion resistance and rigidity to withstand the electrolytic flow. Common tool materials include platinum, titanium, tungsten, tungsten carbide and copper [77].