Electro-chemical

Machining

Introduction

Electrochemical Machining (ECM) is one of the newest

and most useful non-traditional machining (NTM)
process belonging to Electrochemical category.

Is used to machine metals and alloys which are difficult

or impossible to machine by mechanical machining
process.

The reverse of electroplating.

This machining process is based Michael Faradays

classical laws of electrolysis, requiring basically two
electrodes, an electrolyte, a gap and a source of D.C
power of sufficient capacity.

Fig: Schematic illustration of electrochemical machining

Working of ECM

In the actual process of ECM, the cathode is tool shaped(mirror

image of work-piece) and anode is the work-piece.

A gap(0.05 to 0.7 mm) is provided between the tool and workpiece and electrolyte flows through the gap at a velocity of 30 to
60 m/s and it completes the electrical circuit.

Electrolyte is pumped at high pressure of 20 kgf/cm 2(1.96 MPa)

through the gap.

Electrolyte must be circulated at a rate sufficiently high to

conduct current between them and to carry heat.

Metal is removed from the work-piece by dissolution through

electrical action and cathode shape is reproduced on the workpiece.

The electric current is of the order of 50 to 40,000 A at 5

to 35 V D.C for current density of 20 to 300 A/cm2.

Power of 3 KWh is needed to remove 16 cm3 of metal

which is almost 30 times the energy required in the
conventional process(when the material is readily
machinable).

Electrolysis process

In the electrolytic circuit the electron is flow from the

work-piece through the power supply to the tool.

The electrolysis process that takes place at the

cathode liberates hydroxyl ions(OH-) and free
hydrogen.

The hydroxyl ions combine with the metal ions of the

anode to form insoluble metal hydroxides and
material is thus removed from the anode.

At cathode, the following reactions takes place:

1.
2.

M ++ e -

2H++ 2e-

M(M denotes metal)

H2(Hydrogen evolution)

At anode, the following reactions takes place with

a halogen electrolyte:
1.
2.
3.

2H2O
2Cl-

M++ e-(Metal dissolution)

O2+ 4H++ 4e- (Oxygen evolution)
Cl2+ 2e- (Halogen gas evolution)

. As

an example, in machining of iron in NaCl

electrolyte, at the cathode the reaction products
are FeCl2, Fe(OH)2, Fe(OH)3 which forms a layer and
this is how iron is removed by electrolytic action.

. Current

of 1000 A would dissolve iron at the rate of

about 15 g/min and generate hydrogen at a rate of
about 300 cm3/min.

Elements of ECM
Important elements of ECM are:
1.

Electrolyte

2.

Tool (cathode)

3.

Work-piece (anode)

4.

D.C power supply

Electrolyte:

The selection of the ECM electrolyte depends on the

workpiece material, the desired dimensional tolerance,
the surface finish required, and the machining
productivity.

Common electrolytes used are sodium chloride, sodium

nitrate, sodium hydroxide, sodium fluoride, sodium
chlorate, potassium chloride and sulphuric acid.

These solution on reaction produce

compound in the form of sludge.

an

insoluble

The main functions of an electrolyte in ECM are:

1.

It carries the current between tool and work-piece.

2.

It removes the products of machining and other

insoluble products from the cutting region.

3.

It dissipates heat produced in the operation.

4.

Conduct the machining current

The essential characteristics of electrolyte includes:

1.

Good electrical conductivity.

2.

Non-toxicity and chemical stability.

3.

Non-corrosive property.

4.

Low viscosity and high specific heat.

High velocity flow over the electrode surface is one of the

key factors of ECM. It is necessary to prevent crowding of
hydrogen gas and debris of machining.

The choice of the

electrolyte supply method
depends on the
part geometry, machining
method, required accuracy,
and surface finish.

Tool (cathode):

The material used for ECM tools should be electrically conductive and
easily machinable to the required geometry.

The most commonly used tool material are copper, brass, titanium,
copper tungsten and stainless steels when electrolyte is made of salts of
sodium and potassium.

Titanium has been found to be the most suitable tool where the
electrolyte has the tendency to anodize the tool as in case of sulphuric
acid.

The other tool materials are aluminium, graphite, bronze, platinum and
tungsten carbide.

The accuracy of tool shape directly affects the work-piece accuracy.

Electro-forming and cold forging are two methods of tool shaping.

The general requirements of tool material in ECM are:

1.

It should be conductor of electricity.

2.

It should be rigid enough to take up the load due

to fluid pressure.

3.

It should be chemically inert to the electrolyte.

4.

It should be easily machinable to make it in the

desired shape.

Work-piece (anode):

Work-piece should be conductor of electricity. So it is

almost limited to metals only.

Material removal rate:

Material

removal rate (MRR) is an important characteristic to evaluate

efficiency of a non-traditional machining process.
In ECM, material removal takes place due to atomic dissolution of work
material which is governed by Faradays laws of Electrolysis.
m Q and m ECE = A/ v hence m QA/v or ItA/v, So, m = ItA/Fv
IA
m
t
F
but, MRR = =
where
m = ItA/Fv = mass of material dissolve
I = current ; A = Atomic weight ; v = valency
F = Faradays constant = 96500 coulumbs
= density of the material

Power Supply:
1. Type:

direct current

2. Voltage:

2 to 35 V

3. Current:

50 to 40,000 A

4. Current

density: 20 A/cm2 to 300 A/cm2

Accuracy of ECM:

There are number of factors which govern the accuracy

of the parts produced by ECM. The major ones are:
1.

Machining voltage.

2.

Feed rate of electrode (tool).

3.

Temperature of electrolyte.

4.

Concentration of electrolyte.

Under ideal conditions with properly designed tooling,

ECM is capable of holding tolerances of 0.02 mm.

Surface finish in ECM is of the order of 0.2 to 0.8

micron.

No burrs and sharp edges are left on the work-piece.

Application

The most common application of ECM is high accuracy

duplication. Because there is no tool wear, it can be
used repeatedly with a high degree of accuracy.

It is commonly used on thin walled, easily deformable

and brittle material because they would probably
develop cracks with conventional machining.

It is used in machining of hard-heat-resisting alloys.

It is used in cutting cavities and holes in various

products, machining of complex external shapes like
that of turbine blades, aerospace components and
machining of tungsten carbide and nozzles of alloy
steels.

Any conducting material can be machined by this

method.

Advantages

There is no cutting forces therefore clamping is not

required except for controlled motion of the work piece.

It can machine configurations which is beyond the

capability of conventional machining processes.

Very accurate (tolerance of 0.02 mm).

Relatively fast.

Can machine harder metals than the tool.

Extremely thin materials can be easily worked without

distortion.

Tool wear is nearly absent.

Better surface finish (0.2 to 0.8 micron).

Disadvantages

High energy consumption.

Non conducting material cannot be machined.

Corrosion and rust of ECM machine can be

hazardous but preventive measures can help in this
regard.