Electrochemical Machining (ECM) is an advanced manufacturing process that removes electrically conductive material through an electrochemical reaction, ideal for hard or difficult-to-machine materials and complex shapes.
Mind Map
Click to expand
Click to explore the full interactive mind map • Zoom, pan, and navigate
electrochemical machining process
electrochemical machining or ecm is a
method of removing metal by an
electrochemical process
it is normally used for mass production
and is used for machining extremely hard
materials or materials that are
difficult to machine using conventional methods
methods
its use is limited to electrically
conductive materials
this video will cover the following
about electrochemical machining
process 1. working principle
2. construction 3. working
4. applications 5. advantages and disadvantages
disadvantages
working principle whenever the two
electrodes a node which is connected to
positive terminal
and cathode which is connected to
negative terminal is immersed in an electrolyte
electrolyte
such as nacl when the voltage is applied
across the two electrodes the material
removal from the anode starts
the anode and cathode is placed very
close to each other without touching
in ecm the material removal takes place
at atomic level
so it produces a mirror finished surface
ecm working
is opposite to the electrochemical or
galvanic coating
or deposition process
let us understand the chemical reaction
taking place in this process
as the potential difference is applied
across the electrode the movement of
ions starts in between the tool and work piece
piece
the positive ions moves towards the tool
and negative ions move towards the workpiece
workpiece
at cathode the hydrogen ions takes
electrons and gets converted into
hydrogen gas
in the same way the iron atoms comes out
from the anode which is
work piece as fe plus plus ions within
the electrolyte
the sodium ions combines with hydroxyl
ions and form sodium hydroxide and
ferrous ion combined with chloride
ions and forms ferrous chloride also
iron ions combine with hydroxyl
ions and form iron hydroxide in the
electrolyte the fecl2 and
fe o2 produced and gets precipitated in
the form of sludge
and settle down in this way the material
is removed from the workpiece's sludge
the various reactions taking place in
the electrochemical machining process
are as follows
construction electrochemical machining
setup consists of following parts
power supply it requires a dc power
supply for machining purpose
electrolyte the electrolyte has three
main roles in the ecm
process it carries the current between
the tool in the workpiece
it removes the products of the reaction
from the internal electrode gap
and it removes the heat produced from
the passage of the current
tool tool is a replica of the shape
required on the work
piece thank this holds the electrolyte
in which the tool and work piece are immersed
immersed
work piece work piece holding table
pressure gauge it shows the pressure at
which the electrolyte is supplied to the tool
tool
flow meter it shows the rate of flow of
electrolyte to the machining area
flow control valve this helps in
controlling the rate of flow of electrolyte
electrolyte
pressure relief valve in case the
pressure in the supply lines increase
this pressure relief valve opens and
bypasses the electrolyte to the tank
pump pump helps in circulating the electrolyte
electrolyte
reservoir tank stores the electrolyte
filter it helps in filtering the
impurities present in the electrolyte
which may chalk the supply lines
centrifuge it helps in separating the
slug from the electrolyte
slug container stores the slug produced
during the machining process
working of electrochemical machining first
first
the workpiece is assembled in the
fixture and the tool is brought close to
the workpiece
the tool and workpiece is immersed in a
suitable electrolyte
after that a potential difference is
applied across the work piece
which is a node and tool which is
cathode the removal of material starts
the material is removed in the same
manner as we have discussed in the
working principle
tool feed system advances the tool
towards the workpiece
and always keeps a required gap in
between them the material from the
workpiece comes out as positive ions and
combine with the ions present in the
electrolyte and precipitates as sludge
hydrogen gas is liberated at the cathode
during the machining process
since the dissociation of the material
from the work piece takes place at
atomic level
so it gives excellent surface finish the
sludge from the tank is taken out and
separated from the electrolyte the
electrolyte after filtration again
transported to the tank
for the machining process application
the ecm process is used for dye syncing operation
operation
profiling and contouring drilling grinding
grinding
tree panning and micro machining it is
used for machining steam turbine blades
within closed limits
advantages negligible tool wear complex
and concave curvature parts can be
produced easily by the use of convex and
concave tools
no forces and residual stress are
produced because there is no direct
contact between tool and workpiece
an excellent surface finish is produced
less heat is generated
disadvantages the risk of corrosion for tool
tool
work piece and equipment increases in
the case of saw line
and acidic electrolyte electrochemical
machining is capable of machining
electrically conductive materials only
high power consumption high initial
investment cost
if you are new to adtw subscribe our
channel to get all latest updates from us
us
and click on the like button if found
this video useful
also if you want more videos like this
then support our work by sharing our
Click on any text or timestamp to jump to that moment in the video
Share:
Most transcripts ready in under 5 seconds
One-Click Copy125+ LanguagesSearch ContentJump to Timestamps
Paste YouTube URL
Enter any YouTube video link to get the full transcript
Transcript Extraction Form
Most transcripts ready in under 5 seconds
Get Our Chrome Extension
Get transcripts instantly without leaving YouTube. Install our Chrome extension for one-click access to any video's transcript directly on the watch page.
