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ECM Process Parameter 1

1. The document discusses key parameters for electrochemical machining (ECM) including: nature of power supply, tool feed rate, gap between workpiece and tool, and electrolyte properties. 2. It provides details on optimal direct current voltage and current density, maintaining a small uniform gap, and how electrolyte concentration, temperature, and flow affect the process. 3. The document concludes that optimized ECM parameters include a 13wt% NaCl electrolyte concentration, 20V voltage, 0.4kHz frequency, 0.3 duty cycle, 23°C temperature, and 0.5mm/min feed rate to achieve the best 0.912 surface roughness.

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2K views8 pages

ECM Process Parameter 1

1. The document discusses key parameters for electrochemical machining (ECM) including: nature of power supply, tool feed rate, gap between workpiece and tool, and electrolyte properties. 2. It provides details on optimal direct current voltage and current density, maintaining a small uniform gap, and how electrolyte concentration, temperature, and flow affect the process. 3. The document concludes that optimized ECM parameters include a 13wt% NaCl electrolyte concentration, 20V voltage, 0.4kHz frequency, 0.3 duty cycle, 23°C temperature, and 0.5mm/min feed rate to achieve the best 0.912 surface roughness.

Uploaded by

K O
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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ECM Process parameters

1. Nature of power supply

2. Tool feed rate

3. Gap between workpiece and tool

4. Electrolyte
KISHOR O 1
1.Nature of power supply

• Type: direct current


• Voltage: 2 to 35 V
• Current: 50 to 40,000 A
• Current density: 20 A/cm2 to 300 A/cm2
KISHOR O 2
Current density
• Current density is simply the current that can be passed into a
square inch of work area.

• At low current densities , MRR is small.

• The relationship between current density and MRR is shown in fig.

KISHOR O 3
2.Tool feed rate
• Tool in ECM are high electrical and thermal conductivity, corrosion resistance
and rigidity to withstand the electrolytic flow.
• Low frequency tool vibrations were found to improve machining rate and
accuracy
• The effects of tool geometry, electrolyte immersion depth, size and length on
the machining rate, accuracy and gap size
• Inter Electrode Gap always tries to increase due to removal of metal from
workpiece.
• The process always tries to attain the equilibrium gap.
• MRR to avoid short circuit during machining, since short circuit can severely
damage both the micro tool and delicate surface of the workpiece
KISHOR O 4
3. Gap between workpiece and tool

• Maintaining IEG 15to20μm uniformly >>>


to achieve high accuracy and surface finish.
• Metal removal rate is inversely proportional

KISHOR O 5
4.Electrolyte
1.concentration
• A concentrated electrolyte offers low resistance to flow of machining current.
• Metal may be removes beyond the limited.
• The disadvantage is that salts crystallize out of the solution at higher concentration and clog
the are as in the machine enclosure
2.Temperature
• The surface roughness becomes poorer with increasing temperature.
• Electrolyte temperature is higher than 50 °C, the quality of the surface deteriorates.
• Rise in temperature of electrolyte tends to decrease its specific resistance.
• These changes would flow rate/pressure characteristics of the electrolyte.
• Metallurgical property changed due to high temperature
KISHOR O 6
3.Flow of electrolyte

• Nontoxic electrolyte should be used

• electrolyte is pumped from a storage tank via a pressure controller

• delivery systems and multi nozzle systems.

KISHOR O 7
• Conclusion
• with a better surface finish being achieved at frequencies above 400 Hz.

• The optimized parameters for ECM are NaCl concentration 13wt%

• voltage 20 V, frequency 0.4 kHz, duty cycle 0.3, temperature 23 ˚C

• feed rate 0.5 mm/min, and the best surface roughness obtained is 0.912

KISHOR O 8

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