EMAG ECM Basics Engl

EMAG Academy
Seminar
"ECM / PECM" Technology
August, 2016
>1 © EMAG ECM GmbH, 2016

ORGANISATION
EMAG – Worldwide

ORGANISATION
EMAG GMBH & Co. KG
Technology Companies Production Companies Market Companies
EMAG Salach Maschinenfabrik Werkzeugmaschinenfabrik EMAG Salach GmbH, Salach

GmbH Zerbst GmbH Sales and Service EMAG China, Shanghai
Technologie Center for Zerbst
EMAG-, Reinecker-, Karstens-, Sales and service offices
Frankfurt EMAG Korea, Seoul
Kopp and Naxos Union- Leipzig
Products EMAG (China) Machinery Co. Ltd.
Jintan Munich EMAG Thailand
Salach Austria
Denmark Chonburi
KOEPFER EMAG Automation GmbH Sweden
Verzahnungsmaschinen GmbH Automation and Workholding Poland EMAG TAKAMAZ Japan, Ishikawa
Villingen-Schwenningen Technology Czech Republic
Heubach EMAG India
--------------------------------------------------------
EMAG Automation GmbH Bangalore
Technologie Center for EMAG UK
Laser Systems Wolverhampton, GB
Heubach EMAG USA
EMAG NODIER France Farmington Hills
EMAG Leipzig Paris, La Guerche
Technologie Center for EMAG Mexico
Oilfield Components EMAG Zeta Italy Mexico City
Leipzig Milan
EMAG Spain EMAG Brazil

EMAG ECM GmbH Sao Paulo
Technologie Center for Barcelona
ECM / PECM
Gaildorf EMAG OOO
Moskau, RF
EMAG eldec Induction GmbH Belarus
Technologie Center for
Inductive Hardening
Dornstetten

TECHNOLOGIES OF THE EMAG GROUP
EMAG supplies the best manufacturing solutions for precise metal components…..
Turning Milling Grinding Gear Hobbing
Heat Shrink Assembly (P)ECM Technology Laser Welding Inductive Hardening

MACHINE RANGE OF THE EMAG GROUP
MACHINE WORKPIECE-Ø WEIGHT / WORKPIECE
VL 2 - Platform 10 mm (0,4 “)
↓ ↓ ↓
VLC 1200 1200 mm (47 “) 1000 kg (4400 lbs)
Seite 5 ( © EMAG ECM GmbH, 2014)

Topics and contents
Fundamentals of ECM / PECM technology
Structure of an ECM / PECM machine / peripherals
Fixtures / tools
Which materials are good / poor for machining?
Range of workpieces – where does ECM make

sense?
Rival processes and their advantages and
disadvantages
ECM in the chain with traditional processes

Who invented ECM?
Michael Faraday is considered to be the founder of electrochemistry and he coined technical terms such as
electrolysis and electrolyte.
The laws named after him, Faraday's laws, describe the relationship between electrical charges and material
conversion in electrolysis. They are therefore the basic laws of electrolysis.
Michael Faraday was born in London on 22 September 1791.
It was only in 1930, however, that the first application for a patent for an electrochemical sinking process was
made.
ECM technology was first used for industrial applications in the 1950s in the aeronautical and aerospace industry.
In Germany companies such as AEG Elotherm and Robert Bosch then became pioneers of industrial ECM
technology with the manufacture of ECM machines suitable for industry.

How does ECM work?
Electro-chemical Machining
ECM is an electrochemical process used for machining in which the workpiece is worked by means of anodic
dissolution.
Voltage is applied between the tool (cathode, negative pole) and the workpiece (anode, positive pole).
The tool and the workpiece are separated from each other by a gap. They never come into contact with each other.
The flow of current between the anodic workpiece and the cathode (tool) is provided by an electrolyte.
The electrolyte is generally an aqueous common salt (NaCl) – or sodium nitrate (NaNO3) – solution.
When the current flows, metal atoms are oxidized on the surface of the workpiece to form positive metal ions and
normally enter the electrolytes in the form of hydroxides.

How does ECM work?
Anodic dissolution
The chemical formula for the dissolution of iron (Fe) in this case is:
Fe +2H2O → Fe(OH)2 + H2 ↑
(iron plus water results in ferric hydroxide and hydrogen)
The ECM process is in principle suitable for all metals and conductive alloys.
The only exceptions are precious metals such as platinum.
The ECM process involves the use of nothing but current and water.
Metal hydroxides (in the form of sludge), hydrogen gas and heat are formed in the process.

ECM process
> 11 © EMAG ECM GmbH, 2016

EMAG ECM / PECM strengths
Deburring of difficult-to-access bore overlaps Machining of cavities on injection nozzles
Drilling
Reduction of valve plates Machining of engine blades

ECM machining sequence in principle
Workpiece placed in the fixture

Fixture closed, anodic contact with the workpiece, cathode positioned
Electrolyte flow started, short-circuit test
ECM machining started: Power switched on, cathode feed activated if necessary
ECM machining finished: Power switched off
Electrolyte switched off, wait for pressure to drop
Cathode and anodic contacts retracted
Fixture opened
Workpiece removed
Workpiece desalted, cleaned and given corrosion protection

Process characteristics
DC – ECM (direct current) ECM = Electrochemical Machining
U [V]
UDC
Cycle for one part
Pulse – ECM
U [V]
UPuls
UDC
Cycle for one part

t
Process characteristics
PECM = oscillating cathode with pulsed current

(Precision Electrochemical Machining)
z [mm]
max. 1 mm
z0
Cathode movement stroke
from actuation by cam
z1
Machining period t t
U [V]
Pulse package in machining period t

(P)ECM applications (differentiated by cathode movement)
Cathode, static
Deburring (DC or pulsed ECM)
Polishing (Pulsed ECM)
Machining of area patterns (Pulsed ECM)
Machining of cavities (DC or pulsed ECM)
Cathode with infeed

Sinking of 2.5 D forms (DC or pulsed ECM)
Drilling (DC or pulsed ECM)
Cathode with mechanical oscillation and infeed
Precise form reproduction (PECM)

Process characteristics of ECM / PECM
Non-contact machining without thermal or mechanical influences

No cathode wear out, eventually only very low cathode wear out
Surface finish: Rz 0.2 / Ra 0.05 (depending on material)
Reproducibility in cutting depth < 20 µm
Machining on hardened components
Scaleable cycle time thanks to device design
Possible cycle times and infeed rates
Deburring: 20-50 sec.
Reduction / drilling: 0.5 - 5 mm/min
Countersink: 0.01 - 0.3 mm/min

Topics and contents
Fixtures / tools

sense?
disadvantages

Contents
ECM process chain
Machines
Control unit
Filtration / electrolyte management
Cleaning system

ECM process chain
Filtration
ECM process
Electrolyte
Pre-cleaning Secondary cleaning

Applications > ECM machine types
Cathode, static
BI / CI / CS

Cathode with infeed
PT / PO

ECM MACHINE RANGE
The ECM Machine Comfort Standard (CS ) is the best introduction to the
automation of ECM (electro-chemical machining) processes.
■ Modular machine concept
■ Intelligent software and hardware interfaces
■ Starting with manual/semiautomatic operation, the system is
quickly upgraded to full automation
Typical applications:
■ Drilling
■ Machining
■ Deburring
The CS contains these standard:

■ Siemens touch-screen panel
■ Scalable generator technology
■ Conductance monitor
■ Temperature control
■ pH-value control with acid metering
■ Quill stroke with safety interlock
CS
■ Two-handed control button operation
■ Automation interfaces included

EMAG ECM machine types
EMAG CS
- Stainless steel frame
- Protective cover, enclosed at top by suction hood or active
extraction system
- Max. installation height for the fixture - 650 mm.
- Machining area 1100 x 900 mm with lighting
- Leveling feet
- Chip trough beneath the machining area in plastic
- Recirculation pump station
- Machining area trough with clamping rail for securing the fixture.
- Connection for 4 x cathode: 4 x anode; 1x plug (ILME, signals)
- Process valve
- Vertical positioning of basic group
- Quill stroke 320 mm with safety interlock
- Quill clamping face 920 x 320 mm
- Quill closing pressure 4,700 N at 6 bar
- Axis release unit
- Horizontal stroke at 250mm
- Vertical setting, fixed 100mm
- Exhaust air cleaning
- Pneumatic system equipment for valve actuation

Peripherals / Service
Manual machining
Loading by robot
Loading with linear handling system I - ECM machine

II - Electrical cabinet
III - Machining area
IV - Secondary cleaning
V - Secondary preservation
VI - Preliminary purification
VII - Robot
VIII - Linear handling system
Applications > PECM machine types
Cathode, static
CI/ CS

BI/ /CI

BI
Cathode with infeed

Cathode with mechanical oscillation and infeed

PT / PO
Precise form reproduction (PECM)

PECM MACHINE
EQUIPMENT EQUIPMENT
Machine PTS 2500 Machine PT 4000-3
Control (Siemens) 840D sl Control (Siemens) 840D sl
Standard Z axes Standard X,Y,Z axes
Generator DC/Pulse 2500A / 6000A Generator DC/Pulse 4000A / 6000A
Option X,Y,C axes Option C axes
Typical applications in the Aviation-, Automotive- and Precision Engineering Industry:

■ Complicated 2D and 3D contours
*Alternative generator power according to customer request

EMAG PECM machine types
EMAG PT
- Machine base of Mineralit

- Stainless steel machine protection / automatic machining
area doors
- Machine panelling in stainless steel design
- Enclosed machining area
- Z-axis with 250mm travel path
- Pre-tensioned recirculating roller guide rail for infeed stroke
- Hydrostatic guide for the oscillating quill
- Drive and axis area completely enclosed
- Maximum rate of feed 3m/min
- Maximum acceleration 1m/s²
- Maximum infeed force 50kN
- Total stroke 250mm
- Positioning accuracy without compensation <5µm
- Rigidity of the entire axis system >250N/µm
- Feed drive via play-free, pre-tensioned
roller-thread spindle and torque motor
- Oscillation frequency 0-50Hz
- Oscillation stroke 0 to 1.0 mm adjustable or programmable

EMAG PT
Mineralit base
Oscillator
Hydraulic unit
Machining area / fixture
Chip trough/recirculation pump

station

PECM MACHINE RANGE
EQUIPMENT EQUIPMENT
Machine PO 100 SF Machine PO 900 BF
Control (Siemens) 840D sl Control (Siemens) 840D sl
Standard X1-X2 ,Y axes Standard X1-X2 ,Y, Z, B,C
Generator DC/Pulse 2500A / 6000A

Generator DC/Pulse 5000A / 12000A
Typical application in the Aviation industry: Typical application in the Aviation industry:
■ 3D Contour Single foil ■ 3D Contour Blisk
*Alternative generator power according to customer request

PECM bearbeitetes BLISK

Z-axis, 400mm
C-axis (+/-90°)
B-axis (360°) Y-axis, 160mm
Weight: 30 to.
Oscillator unit X1/X2 (stroke 250mm)

PECM Blisk machine PO 900 BF (finish-

machining)

Aviation
Machine concept: EMAG PO 100 S

Aviation / Entwicklung
Machine group concept: EMAG PO 100 S (top view)

EMAG ECM Plant engineering
Control system concept Multi-touch panel

BI / CI / PT
S7 300 machine control system
Profibus analog / digital / Profibus
Control
electronics
Output -
DC generator stages
C battery
- 300 A
+
- 2500 A
Interface I
Interface II

Basic module for pulse

system
Capacitor bank
Output stages

Control system concept -PCU 50.3 (SIEMENS)
PO -OP 015AT, 15" TFT

-MPP 483 control panel
-840Dsl (SIEMENS) -HMI Advanced, WinnCC
flexible
-NCU (continuous path
control, motion control) -input parameters,
ETHERNET operating
-PLC (data flow, process
control, data storage)
-Sinamics drive control EMAG control unit
system
PROFIBUS DP
pulse control unit
(microcontroller
IMPULSE OSCILLATOR based)
power control unit

POWER SUPPLY -
(hardware based)
SINAMICS DRIVE
SIGNAL LINE power supply
unit
workpiece
MOTION CONTROL
POWER CONTROL
PROCESS CONTROL PULSE CONTROL
POWER SUPPLY +
Process : motion control / pH / conductivity / temperature / voltage / current / pulse

Electrolyte
Water quality for electrolyte:

Tap water can normally be used
Max. perm. sulfate concentration in the tap water: 220 mg/l
Ideally distilled water should be used
Salt supply:
Industrial grade sodium nitrate / nitrate of sodium (NaNO3)
from agricultural cooperatives
Acid supply:
nitric acid only (HNO3) 25%
Electrolyte disposal:
disposal via waste management contractor

Overview of media in the ECM process
Metal sludge
Filtration
electrolyte
Electrolyte +
hydroxide
Clean
Sodium nitrate salt /
nitrate of sodium
Tap water or (NaNO3)
Electrolyte
distilled water (concentration approx. 10-20%)
Nitric acid HNO3 25%

for pH-correction

Tasks of the electrolyte
- Provision of electrical conductivity in the gap, i.e. provision of dissociated mobile

ions
- Removal of process heat
- Removal of products of erosion (hydroxide, hydrogen)
Electrolyte variables
Variable Unit or name
Type of salt Sodium nitrate (NaNO3) or common salt (NaCl)
Concentration % wght (percentage weight)
Conductivity mS/cm (Milli-Siemens per centimeter)
pH value pH, e.g. pH8.3
Temperature °C (degrees Celsius)
Pressure 1bar = 10N/cm2= 10000Pa
Flow rate l/min (liters per minute)
All these variables must be kept constant for a stable process.

Filtration - chamber filter press
- Enclosed design
- 470 plate size
- Filter mat, approx. 50 µm
- Filter area, approx. 8 or 16 m2 for 24 or 48 plates
- Supplied by centrifugal pump with pressure and flow monitoring
- Max. flow 30 -40 or 70-80 l/min.

Filtration - chamber filter press

ELECTROLYTE MANAGEMENT SYSTEM
Standard EMS (ECM) Micro EMS (PECM)
*Standard: Electrolyte supply from 40 l/min. up to 600 l/min.

Option: More l/min. according to customer request

MODULAR DESIGN
CHAMBER FILTER PRESS

ELECTROLYTE
MANAGEMENT
CHAMBER FILTER PRESS
ECM / PECM PROCESS ECM / PECM PROCESS ECM / PECM PROCESS

MODULE MODULE MODULE
ECM EQUIPMENT ECM EQUIPMENT ECM EQUIPMENT

PROCESS MONITORING
ECM machining is a stable process with high reproducibility.

This is ensured through the monitoring and control of all process-relevant parameters using the machine control.
Machine (Process) Electrolyte Management System (EMS)

■ Current & Voltage ■ Temperature
■ Electrolyte pressure ■ Conductivity
■ Electrolyte flow ■ ph – Value
■ Electrolyte temperature ■ Cr6 concentration
■ Current monitoring with fast shut down

Microfiltration – system layout
PECM
150 - l/min
20 bar

Microfiltration – method of operation

Microfiltration system

Pre-cleaning
Water quality:
Tap water can be used at all times
What is important is that pure distilled water is never used in the tanks without cleaning agent!
Supply:
Neutral cleaning agent ESKAPHOR N6881
Haug Chemie GmbH,
Disposal:
Bath management and care in accordance with the manufacturer's instructions
Disposal via waste management contractor

Secondary cleaning
Used cleaning agent must be collected separately

and disposed of via a waste management
contractor
Secondary cleaning
(1.5% concentration) Concentrated cleaning agent
Water ESKAPHOR N 6881
approx. 133 L
Total volume approx. 2 L
approx. 135 L

Secondary cleaning
Water quality:
What is important is that pure distilled water is never used in the tanks without cleaning agent!
Supply:
Neutral cleaning agent ESKAPHOR N6881
Haug Chemie GmbH, Breite Strasse 14-16, D-74889 Sinsheim, Tel. +49(0)7261/401-0, Fax +49(0)7261/5624,
info@haugchemie.de, www.haugchemie.de
Disposal:

Corrosion protection
Used dewatering oil must be collected separately

and disposed of via a waste management
contractor
If tested first, dewatering oil can also
be disposed of by a waste management contractor
together with drilling emulsion or
similar.
(100% concentration)
Dewatering oil
DEWATOL 120
Total volume
approx. 135 L
Water accumulating at the bottom of the tank

must be drained off at regular intervals
and disposed of in the same way as for pre-cleaning.

Water quality:
No added water required
Supply:
Dewatering DEWATOL 120
Haug Chemie GmbH, Breite Strasse 14-16, D-74889 Sinsheim, Tel. +49(0)7261/401-0, Fax
+49(0)7261/5624, info@haugchemie.de, www.haugchemie.de
Disposal:
Collect used oil separately

Intermediate rinsing water
Water quality:
Supply:
Normally no need for added cleaning agent
In special cases ESKAPHOR N6881 neutral cleaning agent can be added in small concentrations (approx. 0.3-0.5%)
to protect the components from corrosion during rinsing
Disposal:
If changed frequently, the rinsing water can be disposed of in the sewage system.
Frequently changed means a minimum of 1-2 times per shift (depending on quantities)
To ensure that no limits are exceeded in respect of discharging to the sewage system, it is advisable to analyse a
representative sample of the rinsing water.

Cleaning system:
- Lifting/lowering movements of product
carriers
- Pressurized rinsing on the component at up
to 10 bar
- Ultrasound cleaning
- Heating (at approx. 70°C)
- Automatic media dosing
- Monitoring: Temperature / conductance
- Filtration

Topics and contents
Fixtures / tools

sense?
disadvantages

ECM – Fixture manufacturing
Examples of applications:
Deburring, DC, pulse
Machining of cavities, e.g. nozzles
Precise form reproduction, e.g. turbine blades

Different types of fixture
Individual machining
Multiple machining (cycle time / part )
Column frame, lower part / upper part with vertical cylinder
Operation with axis release unit, catch bolts
Clamping device, cathodes on slide units
Interlock in closed state
Manual / automated loading

Influence on design
Position of component
Cathode geometry, complexity of component
Number of deburring points
Cathode connection, current monitoring channels
Anodic contact, current carrying capacity
Electrolyte, inflow / outflow

Deburring task using a pump housing as an example
View 1 View 2 View 3
3.1
3.2
3.3
3.4
3.5
2.1
1.1
2.2
1.2
View 4 View 5
5.1
5.2
4.1 5.3
4.2 5.4
4.3

View 6 View 7 View 8
8.1
8.2
6.1 7.1
6.2 7.2
View 9 View 10
9.1
9.2 10.1
9.3 10.2
9.4

Deburring device for manual loading (two-hand

operation)

Insulation
Active cathode area

Double pump housing fixture (automation system with gantry loader)
Deburring
100 mm

Double pump housing fixture
Anode connection
Workpiece
Electrolyte inflow
Cathode connection

Double pump housing fixture
Cathode assembly, materials:
Gap 0.5 mm
Feed: PEEK
Cathode coating: Araldite
Cathode: 1.4301 (V2A)

6-unit fixture (automation system with gantry loader)

6-unit fixture (automation system with gantry loader)
2x anode connection / nest
Cathode connection, 3-channel / nest

Single fixture for hub (automation system with gantry loader)
200 mm

4-unit fixture for rotor, loaded by robot
> Machine CI
Deburring > Loaded by robot

> Deburring : 15 sec. / part
> Scaleable cycle time thanks to device design
80 mm

4-unit tool for rotor, loaded by robot
Materials for ECM / PECM tools
PEEK, for components

for contacting parts,
higher precision
components
POM, covers, less

precise components
HGW (composite
fiberglass material), base
plates, cover plates

4-unit fixture for rotor, loaded by robot

Cathode, sandwich – assembly

Material: 1.4301 (V2A)

Anode assembly, materials:
Basic anode body 1.4301 (V2A)
Platinum contact pins, force fitted
Halar coating
PEEK component
mount

24-unit PECM piston guide machining (loaded by robot)
Feed and oscillation
Loading and
unloading
Machining
Workpiece holder

Feed and oscillation
Anode
Anode Cathode

Cathode
Anode

Blisk ECM roughing
Blisk feed movement

Cathode
Pressure
chamber
Electrolyte feed

Topics and contents
Fixtures / tools

sense?
disadvantages

What materials can be machined by ECM?
Materials:
Rust- and acid-resistant steel: 1.4404, 1.4310, 1.4301, 1.4441, 1.4021, 1.4034
Tool steel: 1.2312, 1.2344, 1.2764, 1.2767, 1.6358
Tempering steel: 1.3505, 1.7035, 1.1245
Metals and alloys: Nickel, nickel P, copper, tungsten, gold
Key: Very easy to machine to easy to machine; subject to application
Note:
Steels or alloys with flake or spheroidal graphite, a high carbon or silicon content, and bainitized steels deliver rough surfaces
Titanium and titanium alloys may require special electrolytes or negative pulses.
Restrictions:
Every material requires a matching electrolyte
Surface quality and machinability are dependent on the composition of the alloy and the homogeneity of the structure
Feed rates decrease with increased dissolution
As a general rule:
The more fine-grained the material, the better the surface quality.
Material database

Topics and contents
Fixtures / tools
Which materials are easy / not easy to machine?

sense?

disadvantages

AUTOMOTIVE
TURBO CHARGER INJECTION SYSTEM VALVE DRIVE SYSTEM GEAR

Balancing Machining Drilling Machining
Machining Deburring Machining Drilling
Deburring Deburring Deburring

TURBO CHARGER
ECM BALANCING
Machine CS
Part Turbine Wheel
Cycle time < 60 sec.
Material Inconel
Loading Robot
Tolerance 0,1 gmm
Benefit:
■ Only one iteration step
■ No tool touch necessary
Station 1 Station 2
■ No thermal damage of the material
■ Very low cathode wear in comparison to milling
■ Significant reduction of the reject rate

INJECTION SYSTEM
ECM MACHINING
Machine MPM
Work piece Nozzle
Gantry loader
Loading
(Machine integrated)
Line cycle 15 sec.
Fixture 4 x 4-fold
Benefits ECM gallery forming:

■ No chips and burrs …
■ No machining marks …
■ No thermal damage to the material…
■ Long service life for cathode…
■ Machining of several nozzles simultaniously…

VALVE DRIVE
ECM DRILLING
Machine CS
Workpiece Steel piston
Loading 6-axis robot
Line cycle 28 sec.
ECM drilling:
■ No drilling caps and burr formation…
■ No thermal damage of the material…
■ Long service life for the drilling cathode…
■ For both hard and soft machining…
■ No interrupted cut …
■ Several drillings at the same time…

VALVE DRIVE
ECM DRILLING
Machine CS
Workpiece cam shaft
Loading Manual
Line cycle 102 sec.
34 sec. = 24 holes /
Cycle time
cam shaft
ECM drilling:
■ No drilling caps and burr formation…
■ No thermal damage of the material…
■ Long service life for the drilling cathode…
■ For both hard and soft machining…
■ No interrupted cut …
■ Several drillings at the same time…

Automotive
Advantages of ECM drilling:
No drilling lugs and burr formation
No thermal damage to the material

Elongated hole in cam shaft
Long lasting drill cathode
Suitable for hard and soft machining
Multiple holes can be drilled simultaneously 45° bore hole in flange
Multiple bore holes in cam shaft

VALVE DRIVE (Development)
PECM Machining
Maschine MPM
Work piece Switching cam
Feed rate (finishing) 6 station / 8-fold / 8 mm/min
Tolerance 0,02 mm
Material 100 Cr6
Surface Ra 1
Benefits PECM Machining: PECM machining
■ Machining after hardening…
■ Radial and Axial Machining ...

Twist gearing
■ Fillets possible ...
■ Absolutely burr-free machining ...
■ Almost no tool wear…

Straight gearing
GEAR
ECM DEBURRING
Machine CI
Work Piece Gear
Material Steel
Loading Manual
Cycle time 30sec. (2-fold Fixture)
Deburring Result:
DC - ECM Puls - ECM

120 mm

Inconel material
Inconel is a legally protected brand name of Special Metals Corporation for a range of
corrosion-resistant nickel-based alloys.
Composition
The composition of each product is different. Common to all of them is that nickel is
the main component with chrome being the most important secondary component.
Additional elements: Iron, molybdenum, niobium, cobalt, manganese, copper,

aluminium, titanium, silicon, carbon, sulfur, phosphorous or boron.
Applications
Inconel alloys are widely used in fields involving extremely high temperature loads.
Compressor and turbine blades or combustion chambers in gas turbines are typical
areas of application.
They can also be used in turbochargers.
Source:
http://de.wikipedia.org/wiki/Inconel#Zusammensetzung
Inconel material
Applications
As referred to previously, Inconel alloys are widely used in fields involving
extremely high temperature loads.
Based on the experience of the machining of a compressor rotor (Blisk) made

of Inconel using the EMAG ECM process,
there is now nothing whatsoever standing in the way of ECM machining of

Inconel workpieces such as:
Gas turbines
Aircraft engines
Turbochargers
Heavy-duty pumps

Topics and contents
Fixtures / tools

sense?
disadvantages

Rival deburring processes
Brushing
Advantages: Low-cost procurement; batches of one
Disadvantages: No reproducibility; uncontrolled wear; soiling
Slide grinding
Advantages: Low-cost procurement; no fixture costs; good surfaces
Disadvantages: No reproducibility; no or only limited internal bore overlaps possible
Thermal deburring (TEM)

Advantages: Low fixture costs; high throughput rates
Disadvantages: High procurement costs; gas as the basis is expensive; danger of explosions; low reproducibility;
formation of pearls of slag
Abrasive flow machining (AFM)

Advantages: Very good surfaces; good reproducibility
Disadvantages: High procurement costs; aggressive medium is expensive; limited reproducibility;
relatively high procurement costs; risk
of damage to the workpiece due to incomplete removal of the medium

Rival deburring processes
Deburring with industrial robots

Advantages: Flexible; can be integrated in lines;
Disadvantages: Uncontrolled wear; high procurement costs
Manual deburring
Advantages: No hardware investment; machining in non-productive times also possible
Disadvantages: No or very limited reproducibility; personnel costs
Water-jet deburring
Advantages: No metal forming tools; integrated cleaning process
Disadvantages: Low energy-efficiency (pumps); low reproducibility

Rival machining processes
Erosion
Advantages: Established process; can be used for very small quantities too; very accurate
Disadvantages: Very high wear on the cathode; thermal damage to the workpiece; hard white layer;
limited multiple usage
High speed cutting (HSC)

Advantages: Established process; can be used for small quantities too; very accurate;
user-definable programming
Disadvantages: Tool wear; constraints in terms of machining superalloys
Laser
Advantages: Established process; can be used for small quantities too;
Disadvantages: Thermal damage to the workpiece

Topics and contents
Fixtures / tools

sense?
disadvantages

Motivation
Workpieces with complex shapes often have machining points which are very difficult to access.
Undercuts, cavities or even internal bore hole overlaps are generally no great challenge for machining.
However, this changes if completely burr-free surfaces are required on the workpiece, e.g. for a fuel injection
part, because in these cases the burr has to be completely removed without trace and without any negative
influence on the material even in locations which are difficult to access.
With the mechanical, thermal processes or indeed even the water-jet technology used to date it is not
possible to achieve the envisaged level of productivity or the desired level of cost-effectiveness and
reproducibility.
When it comes to medium and large size production runs in particular, the highest quality is of the essence,
because burrs and burr lugs on the inside can have a negative impact on the operation of components.
Another problem area in practice is that of so-called secondary burrs. In other words, during the process of
removing a burr in a normal machining operation, a follow-up burr or a reverse burr is formed, meaning
undefined finish machining states.
This is why EMAG ECM GmbH firmly advocates the integration of the electrochemical deburring process
directly in the machining line.

ECM deburring unit integrated in a pump housing production line
VSC 250 DUO
SW BA 400-2
EMAG deburring unit

ECM deburring unit for a pump housing production line

EMAG Academy
Thank you for your attention!

EMAG ECM Basics Engl

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

EMAG ECM Basics Engl

Caricato da

Copyright:

Formati disponibili

EMAG Academy

>1 © EMAG ECM GmbH, 2016

>2 © EMAG ECM GmbH, 2016

EMAG GMBH & Co. KG

Technology Companies Production Companies Market Companies

EMAG Salach Maschinenfabrik Werkzeugmaschinenfabrik EMAG Salach GmbH, Salach

EMAG Spain EMAG Brazil

>3 © EMAG ECM GmbH, 2016

Turning Milling Grinding Gear Hobbing

Heat Shrink Assembly (P)ECM Technology Laser Welding Inductive Hardening

>4 © EMAG ECM GmbH, 2016

MACHINE WORKPIECE-Ø WEIGHT / WORKPIECE

Seite 5 ( © EMAG ECM GmbH, 2014)

Fundamentals of ECM / PECM technology

Structure of an ECM / PECM machine / peripherals

Which materials are good / poor for machining?

Range of workpieces – where does ECM make

ECM in the chain with traditional processes

>6 © EMAG ECM GmbH, 2016

Michael Faraday was born in London on 22 September 1791.

>7 © EMAG ECM GmbH, 2016

>8 © EMAG ECM GmbH, 2016

>9 © EMAG ECM GmbH, 2016

> 11 © EMAG ECM GmbH, 2016

Deburring of difficult-to-access bore overlaps Machining of cavities on injection nozzles

Reduction of valve plates Machining of engine blades

> 12 © EMAG ECM GmbH, 2016

Workpiece placed in the fixture

> 13 © EMAG ECM GmbH, 2016

DC – ECM (direct current) ECM = Electrochemical Machining

Cycle for one part

PECM = oscillating cathode with pulsed current

Pulse package in machining period t

> 15 © EMAG ECM GmbH, 2016

Cathode with infeed

Cathode with mechanical oscillation and infeed

Precise form reproduction (PECM)

> 16 © EMAG ECM GmbH, 2016

Non-contact machining without thermal or mechanical influences

Possible cycle times and infeed rates

Deburring: 20-50 sec.

Reduction / drilling: 0.5 - 5 mm/min

Countersink: 0.01 - 0.3 mm/min

> 17 © EMAG ECM GmbH, 2016

Fundamentals of ECM / PECM technology

Structure of an ECM / PECM machine / peripherals

Which materials are good / poor for machining?

Range of workpieces – where does ECM make

ECM in the chain with traditional processes

> 18 © EMAG ECM GmbH, 2016

ECM process chain

Filtration / electrolyte management

> 19 © EMAG ECM GmbH, 2016

Pre-cleaning Secondary cleaning

> 20 © EMAG ECM GmbH, 2016

Machining of area patterns (Pulsed ECM)

> 21 © EMAG ECM GmbH, 2016

The CS contains these standard:

> 22 © EMAG ECM GmbH, 2016

> 23 © EMAG ECM GmbH, 2016

Loading with linear handling system I - ECM machine

Machining of area patterns (Pulsed ECM)

Machining of cavities (DC or pulsed ECM)

Cathode with infeed