Ch 26

26.2 ELECTROCHEMICAL MACHINING PROCESSES

Let's break down each paragraph from the provided text, explaining the
equations and concepts involved:

Paragraph 1: Introduction to Electrochemical Processes An

electrochemical process combines electrical energy with chemical reactions
to remove material, termed electrochemical processes. They operate
inversely to electroplating, where material deposition occurs. For
electrochemical machining (ECM), the work material must conduct
electricity.

Paragraph 2: Basic Process of ECM ECM removes metal from a

conductive workpiece via anodic dissolution. An electrolyte bath flows
between the workpiece and a formed electrode tool. The workpiece acts as
the anode, and the tool as the cathode. Material dissolves from the anode
and deposits onto the cathode in the electrolyte's presence.

Paragraph 3: Equipment and Materials Electrode tools, usually made of

copper, brass, or stainless steel, have an inverse shape to the desired final
part. An allowance is made for the gap between the tool and work.
Electrolytes, often water-based with added salts, reduce resistivity.

Paragraph 4: Process Parameters Key parameters include gap distance,

electrolyte resistivity, current, and electrode frontal area. Gap distance
control is critical for process efficiency. Electrolyte resistivity influences
process speed. Current density dictates the metal removal rate.

Paragraph 5: Equations and Calculations Faraday's Law (Equation 26.1)

relates metal removal volume to current and time. Ohm's Law (Equation
26.3) connects current, voltage, and resistance. The resistance equation
(Equation 26.2) considers gap, resistivity, and surface area. The feed rate
equation (Equation 26.6) calculates electrode advancement rate.
Paragraph 6: Applications and Advantages ECM is ideal for hard metals
and complex geometries. Applications include die sinking, multiple hole
drilling, non-round hole drilling, and deburring. Advantages comprise
minimal surface damage, absence of burrs, low tool wear, and high metal
removal rates.

Paragraph 7: Challenges and Disadvantages ECM demands significant

electrical power and faces challenges in electrolyte sludge disposal.

Each equation contributes to understanding the principles, calculations, and

operational aspects of electrochemical machining. They play vital roles in
designing ECM processes, optimizing parameters, and ensuring efficient
material removal.

Another explanations
26.2 ELECTROCHEMICAL MACHINING PROCESSES

Explanation: This opening segment introduces the topic of

electrochemical machining (ECM) processes. ECM belongs to a
category of nontraditional manufacturing processes that utilize
electrical energy alongside chemical reactions to eliminate
material. Unlike electroplating, where material is deposited onto a
surface, ECM removes material. It's noted that ECM is suitable
only for work materials that conduct electricity.
26.2.1 ELECTROCHEMICAL MACHINING

Explanation: This section delves into the specifics of ECM. It

describes ECM as a method to remove metal from an electrically
conductive workpiece through anodic dissolution. A formed
electrode tool is positioned close to the workpiece but separated
by a flowing electrolyte. The workpiece serves as the anode, and
the tool as the cathode. Material dissolves from the anode and
 deposits onto the cathode in the presence of the electrolyte. ECM
is likened to deplating, where material is removed from the
workpiece rather than added to it. The rapid flow of the
electrolyte prevents material from depositing onto the tool.
Certainly! Let's break down the equation 𝐼=𝐸𝐴𝑔𝑟I=grEA and
explain its significance in the context of electrochemical
machining (ECM):

1. Definition of Terms:
 𝐼I represents the current flowing through the ECM setup,

measured in amperes (amps).

 𝐸E is the voltage applied across the ECM setup, measured in

volts.
 𝐴A denotes the surface area between the workpiece and the

electrode tool within the working frontal gap, measured in

square millimeters (mm²) or square inches (in²).
 𝑔g signifies the gap between the electrode and the

workpiece, measured in millimeters (mm) or inches (in).

 𝑟r represents the resistivity of the electrolyte, measured in

ohm-millimeters (ohm-mm) or ohm-inches (ohm-in).

2. Ohm's Law Application:
 Ohm's Law states that the current flowing through a

conductor is directly proportional to the voltage applied

across it and inversely proportional to its resistance.
 In the context of ECM, the resistance 𝑅R is influenced by the

gap 𝑔g, the resistivity of the electrolyte 𝑟r, and the surface
area 𝐴A between the workpiece and the electrode tool.
3. Relationship between Current, Voltage, Resistance, Gap, and
Surface Area:
  The equation 𝐼=𝐸𝐴𝑔𝑟I=grEA shows the relationship between
current (I), voltage (E), resistance (R), gap (g), and surface
area (A) in an ECM setup.
 It indicates that the current flowing through the ECM process
is directly proportional to the voltage applied ( 𝐸E) and the
surface area (𝐴A) between the workpiece and the electrode
tool.
 Additionally, the current is inversely proportional to the
product of the gap (𝑔g) and the resistivity of the electrolyte
(𝑟r).
 Thus, the equation highlights how factors such as voltage,
gap distance, surface area, and electrolyte resistivity
influence the current density and, consequently, the
efficiency of the ECM process.

In summary, the equation 𝐼=𝐸𝐴𝑔𝑟I=grEA derived from Ohm's Law

illustrates the interplay between current, voltage, resistance, gap
distance, and surface area in electrochemical machining. It
provides insights into the electrical aspects of ECM and helps in
understanding and optimizing the process parameters for efficient
material removal.

1. Specific Removal Rates (Table 26.1): The table presents specific

removal rates (C) for different work materials in ECM, measured in
mm³/amp-sec or in³/amp-min. These rates indicate the volume of
metal removed per unit of electrical current and time, providing
insights into material removal efficiency.
2. Feed Rate Calculation: The paragraph explains the calculation of
feed rate (fr) using the specific removal rate (C), electrode frontal
 area (A), and current (I) as per Equation (26.6). It also highlights
the importance of accounting for efficiency in determining the
actual feed rate.
3. Process Parameters: Key process parameters influencing metal
removal rate and feed rate in ECM are identified, including gap
distance (g), electrolyte resistivity (r), current (I), and electrode
frontal area (A). Controlling these parameters is essential for
optimal ECM performance.
4. Electrolyte and Environmental Considerations: The use of
water-based electrolytes with additives like salts (e.g., NaCl or
NaNO3) to reduce resistivity is discussed. The paragraph also
mentions the disposal challenges associated with the electrolyte
sludge, emphasizing the environmental concerns related to ECM.
5. Power Requirements and Application Areas: ECM requires
significant electrical power due to its reliance on current density
for metal removal. Despite this, ECM finds applications in
scenarios where conventional machining methods are impractical,
such as machining hard or complex geometries.
6. Advantages and Disadvantages: The advantages of ECM,
including minimal surface damage, absence of burrs, low tool
wear, and high metal removal rates for challenging materials, are
listed. However, ECM's disadvantages, such as high power costs
and disposal issues with electrolyte sludge, are also noted.

Overall, the paragraph provides an overview of ECM processes,

highlighting its operational principles, process paramete

Questions
Certainly! Here are questions followed by their answers:
Question 1: What distinguishes electrochemical machining (ECM) from
conventional machining processes?

Answer: ECM utilizes electrical energy along with chemical reactions to

remove material, while conventional machining methods rely solely on
mechanical processes like cutting or grinding.

Question 2: How does ECM achieve material removal from a

workpiece?

Answer: ECM removes metal from an electrically conductive workpiece

through anodic dissolution, where material is dissolved from the
workpiece's surface in the presence of an electrolyte.

Question 3: What role does the electrode tool play in ECM?

Answer: The electrode tool, acting as the cathode, shapes the workpiece by
attracting dissolved metal ions from the anode. It is designed to have the
inverse shape of the desired final part.

Question 4: What is the fundamental principle governing ECM?

Answer: The fundamental principle of ECM is anodic dissolution, wherein

material is selectively removed from the workpiece's surface through
electrochemical reactions facilitated by the flow of electrical current.

Question 5: How do the functions of the anode and cathode differ in

ECM?

Answer: In ECM, the anode refers to the workpiece from which material is
removed through dissolution, while the cathode refers to the electrode tool
where material is deposited.

Question 6: Why is the electrical conductivity of the workpiece crucial

for ECM?
Answer: The workpiece's electrical conductivity is crucial for ECM because it
allows the flow of electrical current necessary for the electrochemical
reactions to occur.

Question 7: What role does the electrolyte bath play in ECM?

Answer: The electrolyte bath facilitates the flow of electrical current, carries
away dissolved metal ions from the workpiece, and helps cool the
machining zone by removing heat generated during the process.

Question 8: What does the term "deplating operation" signify in ECM?

Answer: "Deplating operation" in ECM refers to the selective removal of
material from the workpiece through anodic dissolution, which contrasts
with electroplating where material is deposited onto a surface.

Question 9: What factors influence the efficiency of metal removal in

ECM?

Answer: Factors such as the gap distance between the electrode and
workpiece, the resistivity of the electrolyte, the current density, and the
specific removal rate of the work material influence the efficiency of metal
removal in ECM.

Question 10: Why is the continuous movement of the electrolyte

important during ECM?

Answer: The continuous movement of the electrolyte helps prevent the

deposition of dissolved metal ions onto the electrode tool, carries away
heat generated during the process, and ensures uniform material removal
from the workpiece.

These questions and answers provide a comprehensive understanding of

electrochemical machining (ECM) processes and their key principles. Let me
know if you need further clarification on any of the points!
Question 1: What information is presented in Table 26.1?

Answer: Table 26.1 provides typical values of specific removal rates (C) for
various work materials in electrochemical machining (ECM), measured in
mm³/amp-sec or in³/amp-min.

Question 2: How is the feed rate (fr) calculated in ECM?

Answer: The feed rate (fr) is calculated using the specific removal rate (C),
electrode frontal area (A), and current (I) according to the formula fr = CI/A.

Question 3: Why is it necessary to account for efficiency in

determining the actual feed rate?

Answer: Efficiency needs to be considered because it affects the actual feed

rate. The paragraph mentions that the actual feed rate is the calculated
feed rate multiplied by the efficiency factor (fr = calculated feed rate *
efficiency).

Question 4: What are some of the key process parameters that

influence metal removal rate and feed rate in ECM?

Answer:Key process parameters include gap distance (g), electrolyte

resistivity (r), current (I), and electrode frontal area (A).

Question 5: What environmental challenges are associated with ECM?

Answer: ECM generates electrolyte sludge as a byproduct, which presents
disposal challenges and environmental concerns.

Question 6: Why is significant electrical power required for ECM?

Answer: ECM requires significant electrical power due to its reliance on
current density for metal removal.

Question 7: What are some advantages of ECM over conventional

machining methods?
Answer: Advantages of ECM include minimal surface damage, absence of
burrs, low tool wear, and relatively high metal removal rates for hard and
difficult-to-machine metals.

Question 8: What are some disadvantages of ECM?

Answer: Disadvantages of ECM include the significant cost of electrical

power required and problems associated with the disposal of the
electrolyte sludge.

Question 9: In what applications is ECM commonly used?

Answer: ECM is commonly used in applications where the work metal is

very hard or difficult to machine, or where the workpiece geometry is
complex and challenging for conventional machining methods.

Question 10: What role do electrolytes play in ECM?

Answer: Electrolytes facilitate the flow of electrical current, carry away

dissolved metal ions, cool the machining zone, and aid in the removal of
heat and hydrogen bubbles generated during the process.

These questions and answers cover various aspects of electrochemical

machining (ECM), including its principles, applications, advantages, and
challenges. Let me know if you need further clarification on any of the
points!

26.2.2 ELECTROCHEMICAL DEBURRING AND

GRINDING
Electrochemical Deburring (ECD)

ECD is a process derived from ECM and is aimed at removing

burrs or rounding sharp corners on metal workpieces through
anodic dissolution. In ECD, a setup similar to ECM is used,
focusing on the burr area. The electrolyte flows through the hole
to carry away burr particles, and the cycle times are typically short,
often less than a minute.

Electrochemical Grinding (ECG)

ECG is a specialized form of ECM where a rotating grinding wheel

with a conductive bond material enhances anodic dissolution.
Abrasives like aluminum oxide and diamond are used, and the
abrasive grits protrude from the grinding wheel, establishing the
gap distance. Deplating accounts for most of the metal removal,
with the abrasive action removing the rest, mainly in the form of
salt films formed during electrochemical reactions.

Advantages of ECG

Since most of the machining is done by electrochemical action,

the grinding wheel in ECG lasts longer compared to conventional
grinding, resulting in a higher grinding ratio. Additionally,
dressing of the grinding wheel is required much less frequently.

Applications of ECG

ECG finds applications in sharpening cemented carbide tools and

grinding surgical needles, thin-wall tubes, and fragile parts.

Question 1: What is electrochemical deburring (ECD) and what is its

purpose? Answer: Electrochemical deburring (ECD) is a process adapted
from ECM, aimed at removing burrs or rounding sharp corners on metal
workpieces through anodic dissolution.
Question 2: How does ECD operate, and what factors affect its cycle
time?

Answer: In ECD, the electrolyte flows through the hole to carry away burr
particles. The cycle times are typically short, often less than a minute,
influenced by the amount of material to be removed and the desired
surface finish.

Question 3: What is electrochemical grinding (ECG), and how does it

differ from conventional grinding

Answer: ECG is a specialized form of ECM where a rotating grinding wheel

with a conductive bond material enhances anodic dissolution. It differs from
conventional grinding as it primarily operates through electrochemical
action rather than mechanical abrasion.

Question 4: What materials are commonly used as abrasives in ECG,

and how are they applied?

Answer: Abrasives such as aluminum oxide and diamond are used in ECG.
They are applied through a rotating grinding wheel with abrasive grits
protruding from it, establishing the gap distance for electrolyte flow.

Question 5: What is the main mechanism responsible for metal

removal in ECG, and what role does the grinding wheel play?

Answer: Deplating is responsible for most of the metal removal in ECG,

while the grinding wheel removes the rest, primarily in the form of salt films
formed during electrochemical reactions.

Question 6: What are some advantages of electrochemical grinding

(ECG) over conventional grinding methods?

Answer: ECG offers advantages such as longer-lasting grinding wheels,

resulting in a higher grinding ratio, and reduced frequency of dressing the
grinding wheel.
 Question 7: What are some applications of electrochemical grinding
(ECG)? Answer: ECG finds applications in sharpening cemented carbide
tools and grinding surgical needles, thin-wall tubes, and fragile parts.

Feel free to ask if you have any more questions or need further clarification!

Questions of exercise
Question 26.1: Why are the nontraditional material removal
processes important?
Answer: Nontraditional material removal processes are
important because they offer alternative methods for machining
materials that are difficult or impossible to machine using
conventional methods. They provide solutions for machining
hard and brittle materials, complex shapes, and delicate
components, thus expanding the capabilities of manufacturing
industries.
Question 26.2: There are four categories of nontraditional
machining processes, based on principal energy form. Name
the four categories.
Answer: The four categories of nontraditional machining
processes based on principal energy form are:

1. Mechanical energy processes

2. Electrical energy processes
3. Thermal energy processes
4. Chemical energy processes

Question 26.3: How does the ultrasonic machining process

work?
 Answer: In ultrasonic machining, high-frequency vibrations of
an ultrasonic tool are transmitted to abrasive particles mixed
with a liquid medium. These abrasive particles impact the
workpiece at high velocities, causing material removal through
abrasion.
Question 26.4: Describe the water jet cutting process.

Answer: Water jet cutting involves using a high-pressure stream

of water to cut through materials. The water jet, typically mixed
with abrasive particles for enhanced cutting, is directed at the
workpiece to erode and remove material, resulting in precise and
clean cuts.
Question 26.5: What is the difference between water jet
cutting, abrasive water jet cutting, and abrasive jet cutting?
Answer: Water jet cutting uses a high-pressure stream of water
for cutting, while abrasive water jet cutting involves mixing
abrasive particles with the water stream to enhance cutting
efficiency. Abrasive jet cutting uses abrasive particles propelled
by a gas stream to cut materials.
Question 26.6: Name the three main types of electrochemical
machining.
Answer: The three main types of electrochemical machining
are:

1. Electrochemical machining (ECM)

2. Electrochemical deburring (ECD)
3. Electrochemical grinding (ECG)
Question 26.7: Identify the two significant disadvantages of
electrochemical machining.
Answer: The two significant disadvantages of electrochemical
machining are the significant cost of electrical power required to
drive the operation and the disposal of the electrolyte sludge
produced during the process.
Question 26.8: How does increasing discharge current affect
metal removal rate and surface finish in electric discharge
machining?
Answer: Increasing discharge current in electric discharge
machining (EDM) generally increases the metal removal rate but
may negatively impact the surface finish by causing more
aggressive material removal and potentially larger craters on the
workpiece surface.
26.1. Which of the following processes use mechanical energy as the
principal energy source (three correct answers):

(c) Conventional milling

(d) Ultrasonic machining
(e) Water jet cutting

26.2. Ultrasonic machining can be used to machine both metallic

and nonmetallic materials:
(b) False

26.3. Etch factor is equal to which of the following in chemical

machining (more than one):

(a) Anisotropy
26.7. Of the following processes, which one is noted for the highest
material removal rates:

(g) Water jet cutting

26.8. Which one of the following processes would be appropriate to

drill a hole with a square cross section, 0.25 inch on a side and 1-
inch deep in a steel workpiece:

(g) Wire EDM

26.9. Which of the following processes would be appropriate for

cutting a narrow slot, less than 0.015 inch wide, in a 3/8-in-thick
sheet of fiber-reinforced plastic (two best answers):

(a) Abrasive jet machining

(f) Water jet cutting

26.10. Which one of the following processes would be appropriate

for cutting a hole of 0.003 inch diameter through a plate of
aluminum that is 1/16 in thick:

(d) Laser beam machining

26.11. Which of the following processes could be used to cut a large

piece of 1/2-inch plate steel into two sections (two best answers):

(e) Oxyfuel cutting

(f) Water jet cutting