Electrochemical Machining Seminar Report PPT Download
• A popular application of electrolysis is the electroplating process in which metal coatings are deposited upon the surface of a catholically polarized metal.
• ECM is similar to electro polishing in that it also is an anodic dissolution process. But the rates of metal removal offered by the polishing process are considerably less than those needed in metal machining practice .
• Metal removal is achieved by electrochemical dissolution of an anodically polarized workpiece which is one part of an electrolytic cell in ECM.
• when an electric current is passed between two conductors dipped into a liquid solution named as Electrolysis .
• Electrolytes are different from metallic conductors of electricity in that the current is carried not by electrons but by atoms, or group of atoms, which have either lost or gained electrons, thus acquiring either positive or negative charges. Such atoms are called ions.
Electrolytic dissolution of iron.
• Ions which carry positive charges move through the electrolyte in the direction of the positive current, that is, toward the cathode, and are called cat anions.
• The negatively charged ions travel toward the anode and are called anions.
• The movement of the ions is accompanied by the flow of electrons, in the opposite sense to the positive current in the electrolyte.
• Both reactions are a consequence of the applied potential difference, that is, voltage, from the electric source.
• the workpiece and tool are the anode and cathode, respectively, of an electrolytic cell, and a constant potential difference, usually at about 10 V, is applied across them.
• A suitable electrolyte, for example, aqueous sodium chloride (table salt) solution, is chosen so that the cathode shape remains unchanged during electrolysis.
• The electrolyte is also pumped at a rate 3 to 30 meter/second, through the gap between the electrodes to remove the products of machining and to diminish unwanted effects, such as those that arise with cathodic gas generation and electrical heating.
• The rate at which metal is then removed from the anode is approximately in inverse proportion to the distance between the electrodes
• As machining proceeds, and with the simultaneous movement of the cathode at a typical rate, for example, 0.02 millimeter/second toward the anode.
• the gap width along the electrode length will gradually tend to a steady-state value. Under these conditions, a shape, roughly complementary to that of the cathode, will be reproduced on the anode.
ECM Components (Power)
• The power needed to operate the ECM is obviously electrical. There are many specifications to this power.
• The current density must be high.
• The gap between the tool and the work piece must be low for higher accuracy, thus the voltage must be low to avoid a short circuit.
• The control system uses some of this electrical power.
ECM Components (electrolyte circulation system)
• The electrolyte must be injected in the gap at high speed (between 1500 to 3000 m/min).
• The inlet pressure must be between 0.15-3 MPa.
• The electrolyte system must include a fairly strong pump.
• System also includes a filter, sludge removal system, and treatment units.
• The electrolyte is stored in a tank.
ECM Components (control system)
• Control parameters include:
– Inlet and outlet pressure of electrolyte
– Temperature of electrolyte.
– The current is dependant on the above parameters and the feed rate.
• There is no cutting forces therefore clamping is not required except for controlled motion of the work piece.
• There is no heat affected zone.
• Very accurate.
• Relatively fast
• Can machine harder metals than the tool
• Faster than EDM
• No tool wear at all.
• No heat affected zone.
• Better finish and accuracy.
• More expensive than conventional machining.
• Need more area for installation.
• Electrolytes may destroy the equipment.
• Not environmentally friendly (sludge and other waste)
• High energy consumption.
• Material has to be electrically conductive.
• 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 also used to make cavities and holes in various products.
• Sinking operations (RAM ECM) are also used as an alternative to RAM EDM.
• It is commonly used on thin walled, easily deformable and brittle material because they would probably develop cracks with conventional machining.
• The two most common products of ECM are turbine/compressor blades and rifle barrels.
• Each of those parts require machining of extremely hard metals with certain mechanical specifications that would be really difficult to perform on conventional machines.
• Some of these mechanical characteristics achieved by ECM are:
– Stress free grooves.
– Any groove geometry.
– Any conductive metal can be machined.
– Repeatable accuracy of 0.0005”.
– High surface finish.
– Fast cycle time.
• The process is economical when a large number of complex identical products need to be made (at least 50 units).
• Several tools could be connected to a cassette to make many cavities simultaneously. (i.e. cylinder cavities in engines).
• Large cavities are more economical on ECM and can be processed in 1/10 the time of EDM.