Chemical and Electro-Chemical Energy Based Processes Presentation slide for courses, classes, lectures et al. Chemical and Electro-Chemical Energy Based Processes

Electrochemical Machining The reverse of electroplating An electrolyte acts as current carrier and the high rate of electrolyte movement in the tool washes metal ions away from the workpiece (anode) before they have a chance to plate onto the tool (cathode) The material-removal rate (MRR) in electrochemical machining is I = current in amperes C = material constant

Electrochemical Machining Electrochemical machining (ECM) removes material by anodic dissolution with a rapidly flowing electrolyte The tool is the cathode and the workpiece is the electrolyte

Electrochemical Machining Process Capabilities Used to machine complex cavities and shapes in high- strength materials Aerospace industry for the mass production of turbine blades, jet-engine parts and nozzles Modification of ECM, shaped-tube electrolytic machining (STEM), is used for drilling small-diameter deep holes ECM process leaves a burr-free, bright surface and can be used as a deburring process Available as numerically controlled machining centers with high production rates, high flexibility, and close dimensional tolerances

Process Capabilities

Electrochemical Machining

ECM Electrochemical machining (ECM) is an electrolytic material removal process involving a negatively charged shaped electrode (cathode), a conductive fluid (electrolyte), and a conductive workpiece (anode). ECM is characterized as "reverse electroplating."  The tool must be properly shaped, and provision for waste removal must be made. 6/25/2018

ECM Electrochemical machining (ECM) has been developed initially to machine these hard to machine alloys, although any metal can so be machined. ECM is an electrolytic process and its basis is the phenomenon of electrolysis, whose laws were established by Faraday in 1833. The first significant developments occurred in the 1950s, when ECM was investigated as a method for shaping high strength alloys.

Working Uses an electrolyte and electrical current to ionize and remove metal atoms Can machine complex cavities in high-strength materials Leaves a burr-free surface Not affected by the strength, hardness or toughness of the material

As the tool approaches the work piece it erodes the negative shape of it. Thus complex shapes are made from soft copper metal and used to produce negative duplicates of it. This process is called electrochemical sinking

The tool may also be connected to a CNC machine to produce even more complex shapes with a single tool