ELECTROCHEMICAL DISCHARGE

MACHINING(ECDM) USING SIDE

INSULATED TOOL ELECTRODE
Department of Mechanical
Engineering

Submitted by,
Guided by, Krishna Das T
Mr. Syed Muhammed Fahd 8360
M8A

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 CONTENTS
 Introduction
 Experimental Set Up
 Mechanism
 Main influencing parameters
 Side insulated tool electrodes
 Advantages
 Disadvantages
 Application of ECDM
 Conclusion
 References

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 Introduction
• Electrochemical discharge machining (ECDM)
is a hybrid micro machining process that
combines the features of electro chemical
machining (ECM) and electro discharge
machining (EDM).
• Side-insulated electrodes are used to
eliminate the discharge through the side wall
by insulating the electrode sidewall.

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Experimental Set Up for ECDM

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Mechanism

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.

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CONTRIBUTION OF PROCESS
PARAMETERS ON MRR
(M .L .Harugade ,M .V .Kavade ,N.V. Hargude ,2013)

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 Side insulated tool electrodes
• In tradition ECDM process, the bubbles are produced not only at the
electrode front end, but also around the sidewall .
• In side insulation the bubbles will only be produced in the front end of the
electrode. This reduces the heating produced in the sidewall.

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Holes obtained using
different electrodes

Fig (a) hole produced using traditional

electrode.
Fig (b) hole produces using side-
insulated electrode.

• The holes produced by

traditional electrode has
a tapered shape due
side discharge.
• Side discharge promotes
heat assisted chemical
etching.

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 Effects in the machining process
• In traditional ECDM due to side discharge micro grooves will
be produced .(Weidong Tang, Xiaoming Kang ,Wansheng
Zhao,2017).
• This can be reduces in side insulated process

Traditional ECDM Side insulated electrode ECDM 10

 Heat affected zone (HAZ)
In the HAZ the material is
generally removed by heat
Assisted chemical etching.

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 Advantages of ECDM
• Better surface finish.
• Suitable for non-conducting materials.
• High accuracy (.01mm).
• Less power consumption (3-4A,40V,DC).
• Does not leave any chips or burrs.

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 Disadvantages of ECDM
• Chances to electrode wear.
• Initial cost is high.
• Energy from the spark is not fully transferred.
• Radial overcut.

WC tool wear on
different voltages
(a)51V (b)53V (c) 54V
(d)55V (e)56V (f)58V

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 Applications of ECDM
• Through and blind micro-holes
• Micro-grooves
• Micro-slots
• Micro-channels and complex shapes produced
in non conducting materials
• Trueing and Dressing of grinding wheels
• Micro electro seam welding for copper plate

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 Conclusion
• By using side insulation discharge through the
sides can be eliminated .
• Surface integrity of material will be better
when using side insulated tool electrode,
formation of micro grooves in HAZ reduces the
surface integrity when using traditional
electrodes
• Tapering produced while machining can also
be limited by using side insulation.

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 References
• M .L .Harugade ,M .V .Kavade and N.V. Hargude (2013).An Experimental
Investigation of Effect of Electrolyte Solution On Material Removal Rate in
ECDM,International Journal of Engineering and Technology, Vol2 Issue1.
• R. Wuthrich , V. Fascio(2004). Machining of non-conducting materials
using Electrochemical Discharge phenomenon-an overview . International
Journal of Machine Tools and Manufacture 45(2005)1095-1108
• Tushar D. Shinde, Prof. A. K.Mahindrikar(2015). Review Paper on Effect of
Process Parameters of ECDM on Response Variables , International Journal
of Innovation in Engineering ,Research and Technology .
• Weindong Tang , Xiaoming Kang and Wansheng Zhao (2017).Enhancement
of electrochemical discharge machining and accuracy and surface integrity
using side-insulated tool electrode with diamond coating. Journal on
Micromechanics and Microengineering.

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