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

2. 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

3. 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

4. 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

5. Process Capabilities

6. Electrochemical Machining

7. 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

8. 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.

9. 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

10. 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

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