0:07 electrochemical machining process
0:10 electrochemical machining or ecm is a
0:12 method of removing metal by an
0:14 electrochemical process
0:16 it is normally used for mass production
0:18 and is used for machining extremely hard
0:20 materials or materials that are
0:22 difficult to machine using conventional methods
0:22 methods
0:24 its use is limited to electrically
0:26 conductive materials
0:28 this video will cover the following
0:30 about electrochemical machining
0:33 process 1. working principle
0:36 2. construction 3. working
0:40 4. applications 5. advantages and disadvantages
0:43 disadvantages
0:45 working principle whenever the two
0:47 electrodes a node which is connected to
0:48 positive terminal
0:49 and cathode which is connected to
0:51 negative terminal is immersed in an electrolyte
0:52 electrolyte
0:56 such as nacl when the voltage is applied
0:58 across the two electrodes the material
1:00 removal from the anode starts
1:02 the anode and cathode is placed very
1:04 close to each other without touching
1:07 in ecm the material removal takes place
1:08 at atomic level
1:10 so it produces a mirror finished surface
1:12 ecm working
1:14 is opposite to the electrochemical or
1:15 galvanic coating
1:18 or deposition process
1:20 let us understand the chemical reaction
1:22 taking place in this process
1:24 as the potential difference is applied
1:26 across the electrode the movement of
1:28 ions starts in between the tool and work piece
1:29 piece
1:31 the positive ions moves towards the tool
1:33 and negative ions move towards the workpiece
1:34 workpiece
1:36 at cathode the hydrogen ions takes
1:38 electrons and gets converted into
1:39 hydrogen gas
1:41 in the same way the iron atoms comes out
1:43 from the anode which is
1:46 work piece as fe plus plus ions within
1:47 the electrolyte
1:49 the sodium ions combines with hydroxyl
1:52 ions and form sodium hydroxide and
1:54 ferrous ion combined with chloride
1:56 ions and forms ferrous chloride also
1:58 iron ions combine with hydroxyl
2:01 ions and form iron hydroxide in the
2:03 electrolyte the fecl2 and
2:06 fe o2 produced and gets precipitated in
2:07 the form of sludge
2:10 and settle down in this way the material
2:13 is removed from the workpiece's sludge
2:15 the various reactions taking place in
2:16 the electrochemical machining process
2:22 are as follows
2:25 construction electrochemical machining
2:27 setup consists of following parts
2:30 power supply it requires a dc power
2:32 supply for machining purpose
2:35 electrolyte the electrolyte has three
2:36 main roles in the ecm
2:38 process it carries the current between
2:40 the tool in the workpiece
2:42 it removes the products of the reaction
2:44 from the internal electrode gap
2:46 and it removes the heat produced from
2:48 the passage of the current
2:50 tool tool is a replica of the shape
2:51 required on the work
2:54 piece thank this holds the electrolyte
2:56 in which the tool and work piece are immersed
2:57 immersed
3:01 work piece work piece holding table
3:03 pressure gauge it shows the pressure at
3:05 which the electrolyte is supplied to the tool
3:06 tool
3:09 flow meter it shows the rate of flow of
3:11 electrolyte to the machining area
3:13 flow control valve this helps in
3:14 controlling the rate of flow of electrolyte
3:16 electrolyte
3:18 pressure relief valve in case the
3:20 pressure in the supply lines increase
3:22 this pressure relief valve opens and
3:25 bypasses the electrolyte to the tank
3:27 pump pump helps in circulating the electrolyte
3:29 electrolyte
3:32 reservoir tank stores the electrolyte
3:34 filter it helps in filtering the
3:36 impurities present in the electrolyte
3:39 which may chalk the supply lines
3:41 centrifuge it helps in separating the
3:43 slug from the electrolyte
3:46 slug container stores the slug produced
3:48 during the machining process
3:51 working of electrochemical machining first
3:52 first
3:53 the workpiece is assembled in the
3:55 fixture and the tool is brought close to
3:56 the workpiece
3:58 the tool and workpiece is immersed in a
4:00 suitable electrolyte
4:02 after that a potential difference is
4:03 applied across the work piece
4:05 which is a node and tool which is
4:08 cathode the removal of material starts
4:10 the material is removed in the same
4:11 manner as we have discussed in the
4:13 working principle
4:15 tool feed system advances the tool
4:16 towards the workpiece
4:18 and always keeps a required gap in
4:20 between them the material from the
4:22 workpiece comes out as positive ions and
4:24 combine with the ions present in the
4:27 electrolyte and precipitates as sludge
4:29 hydrogen gas is liberated at the cathode
4:31 during the machining process
4:33 since the dissociation of the material
4:34 from the work piece takes place at
4:35 atomic level
4:38 so it gives excellent surface finish the
4:40 sludge from the tank is taken out and
4:42 separated from the electrolyte the
4:44 electrolyte after filtration again
4:45 transported to the tank
4:48 for the machining process application
4:51 the ecm process is used for dye syncing operation
4:52 operation
4:55 profiling and contouring drilling grinding
4:56 grinding
4:59 tree panning and micro machining it is
5:01 used for machining steam turbine blades
5:03 within closed limits
5:06 advantages negligible tool wear complex
5:08 and concave curvature parts can be
5:11 produced easily by the use of convex and
5:12 concave tools
5:14 no forces and residual stress are
5:16 produced because there is no direct
5:18 contact between tool and workpiece
5:21 an excellent surface finish is produced
5:24 less heat is generated
5:27 disadvantages the risk of corrosion for tool
5:27 tool
5:29 work piece and equipment increases in
5:30 the case of saw line
5:33 and acidic electrolyte electrochemical
5:35 machining is capable of machining
5:38 electrically conductive materials only
5:40 high power consumption high initial
5:42 investment cost
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