BEDMM

BRUSH ELECTRIC DISCHARGE MECHANICAL

MACHINING

BEDMM

ECM

ECD
Phase

Ions

Friction

MA
Phase

Brush

Metal Brush Tool

Workpiece

EDM
EDE
Phase

Plasma

Utilizes elastic discrete electrodes made as a

brush that rotates in a water-glass solution.

This was first introduced by Nowicki et al. [56] for

machining complex shapes with large variation of
shapes and dimensions in which case EDG or EDM
cannot be efficiently used.

Advantages - random nature of the frequency

and encounter of electrodes with the workpiece,
the periodic contact between the electrode and
the workpiece and the current flow through this
[56]

It involves three phenomena happening

simultaneously:

electrochemical dissolution,

electrodischarge thermal process

mechanical contact through friction

The frictional contact is the most important in this process

A damaging anodic layer of silicon is formed that if not

removed, it leads to etching and mating between the
electrodes

When peaks of roughness occur in an ongoing machining

process, the current supply can be switched off without
stopping rotation and frictional contact quickly polishes
and finishes the workpiece while at the same stand and
equipment

Disadvantages of ECM

A huge amount of energy is consumed (about 100 times that required

for turning or drilling steel).

Metal removal rates are slow compared with conventional methods.

ECM can only be applied to electrically conductive workpiece materials.

There are difficulties in safely removing and disposing of the explosive

hydrogen gas generated during machining.

The workpiece needs to be cleaned and oiled immediately after
machining.
There are difficulties with handling and containing the electrolyte,
which may attack the equipment.
It is not easy to duplicate the shape of the tool electrode in the workpiece
with a high degree of accuracy because of the side machining effect.

The process cant produce sharp internal or external edges.

The pumping of high-pressure electrolyte into the narrow machining

gap gives rise to large forces acting on the tool and the workpiece

Disadvantages of EDM

The slow rate of material removal.

Potential fire hazard associated with use of
combustible oil based dielectrics.
The additional time and cost used for creating
electrodes for ram/sinker EDM.
Reproducing sharp corners on the workpiece is
difficult due to electrode wear.
Specific power consumption is very high.
Power consumption is high.
"Overcut" is formed.
Excessive tool wear occurs during machining.
Electrically non-conductive materials can be
machined only with specific set-up of the process