STUDY OF THE METHODS OF IMPROVING

MATERIAL REMOVAL RATE

IN
ELECTROCHEMICAL MACHINING
BY Surekar S H Kharche W G

Electrochemical machining (ECM)

Controlled anodic dissolution process

* Very Effective for Difficult-to-cut Materials * High Removal Rates * Easy to Generate Complicated Contours & Profiles * No Tool Wear, No Burrs and No Scratches

Electrochemical machining (ECM)

Material Removal Rate: From the Fardays law M=kIt Where K is electrochemical equivalent (A/Z.F) M is the mass I is Current t is machining time A atomic weight of dissolving ions Z is valance of dissolved ions F is Faradays constant
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Electrochemical machining (ECM)

Factors influencing MRR( Material Removal Rate) Composition and Flow Rate of Electrolyte Current Density Inter Electrode Gap(IEG) and Voltage across it Feed Rate

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Electrochemical machining (ECM)

Material Removal Rate is affected by Passivation Effects at the Anode Surface Passivation is Formation of Thin Film of Oxides and Gases near the Anode Surface Passivation Inhibits the Material Removal Mechanism

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Electrochemical machining (ECM)

Electrochemical reactions during ECM of iron in sodium chloride (NaCl) electrolyte (8)

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Electrochemical machining (ECM)

Depassivation helps in Improving MRR by increasing the current flow in IEG.

Methods of Depassivation

Chemical Depassivation

Hydrodynamic Depassivation Mechanical Depassivation Electrical Depassivation Compound Methods

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Electrochemical machining (ECM)

Chemical Depassivation
Addition of chemical elements can change the electrolyte properties Conductivity, Concentration, pH etc. become Uncontrollable

Hence not suitable

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Electrochemical machining (ECM)

Hydrodynamic Depassivation Flow of electrolyte is optimised to avoid the passivation to some extent. Further improvement is possible by other methods.

Electrochemical machining (ECM)

Mechanical Depassivation
Addition of Abrasive Particles in Electrolyte Studies have shown good improvement in MRR

Electrochemical machining (ECM)

Depassivation by Combined Methods ECM With EDM (ECDM) ECM with Vibratory Tool(ECUSM) ECM with Ultrasonic Electrolyte Bath ECDM and ECUSM are being studied recently, improvement in MRR has been observed

Electrochemical machining (ECM)

Electric Depassivation Pulsed Current - Periodically changing potential difference across the IEG

Pulsed Reverse Current -Periodically changing potential difference across the IEG and polarity

Pulsed Electrochemical machining

Short pulses of Voltage across the IEG

On time is Approximately 60 70% Off time helps in depassivation but reduces the net MRR

Pulsed Electrochemical machining

Short pulses of Voltage across the IEG

On time is Approximately 60 70% Off time helps in removing sludge and small amount of depassivation Reduces the net MRR Improved geometry of product

Pulsed Electrochemical machining

Electrochemical machining
PECM with Bipolar current PRECM

Short pulses of Bipolar current across the IEG

On time is Approximately 60 70% Off time and reverse polarity time 30-40% Reverse polareity helps in depassivation and improves MRR

Pulsed Electrochemical machining

Bipolar current Wave Form

Electrochemical machining (ECM)

COMPARISION OF PARAMETERS IN DCECM, PCECM & PRECM

Process

DECM PECM PRECM

Current Density A/cm2 71-57 61-49 69-58

MRR (depth) m /sec. 7.08 6.97 9.93

Surface Roughness Ra m 0.60 0.77 0.18

Source: C.D. Zhou, E.J. Taylor, J. J. Sun, L. Gebhart, E.C. Stortz, and R.P. Renz , Electrochemical Machining of Hard Passive Alloys With Pulse Reverse current, Faraday Technology, Inc., Transactions of NAMRI/SME, Volume XXV, 1997
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References : 1] American Society for Metals, MACHINING-HANDBOOK, Page No.149-155 VOL- 3,9th Edition [2] American Society for Metals, MACHINING-HANDBOOK, Page No.147-155, VOL-16,8th Edition [3] DAN NICOARA, ALEXANDRU HEDES, IOAN SORA, Ultrasonic Enhancement of an Electro chemical Machining Process, Proceedings of the 5th WSEAS International Conf. on Applications of Electrical Engineering, Prague, Czech Republic, March 12-14, 2006 (pp213-218) [4] C.D. Zhou, E.J. Taylor, J. J. Sun, L. Gebhart, E.C. Stortz, and R.P. Renz , Electrochemical Machining of Hard Passive Alloys With Pulse Reverse Current, Faraday Technology, Inc., Transactions of NAMRI/SME, Volume XXV, 1997 [5] US Patent 6402931B1, Electrochemical Machining Using Modulated Reverse Electric Fields, Jun 11, 2002 [6] Jenny J. Sun Larry E. Gebhart Robert P. Renz E. Jennings Taylor Maria E. Inman, The Applications of CM-ECM Technology to Metal Surface Finishing, Faraday Technology, Inc. Transactions of NAMRI/SME Volume XXVIIII, 2000 [7] Joseph McGeough, ELECTROCHEMICAL MACHINING (ECM), Electrochemistry Encyclope dia,http://electrochem.cwru.edu/encycl/art-m03machining.htm [8] http://www.unl.edu/nmrc/ecmreferences.htm, 18/6/2004
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THANK YOU