MODULE 3

ELECTROCHEMICAL MACHINING (ECM)

INTRODUCTION
Electrochemical machining (ECM) is a metal-removal process based on the
principle of reverse electroplating. In this process, particles travel from the
anodic material (workpiece) toward the cathodic material (machining tool).
A current of electrolyte fluid carries away the deplated material before it has
a chance to reach the machining tool.
The cavity produced is the female mating image of the tool shape.

ECM process

Similar to EDM, the workpiece hardness is not a factor, making ECM suitable
for machining difficult-to –machine materials. Difficult shapes can be made
by this process on materials regardless of their hardness. A schematic
representation of ECM process is shown in Figure. The ECM tool is positioned
very close to the workpiece and a low voltage, high amperage DC current is
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 passed between the workpiece and electrode. Some of the shapes made by
ECM process is shown in Figure.
Material removal rate, MRR, in electrochemical machining:

MRR = C .I. h (cm 3/min)

C: specific (material) removal rate (e.g., 0.2052 cm 3/amp-min for nickel);
I: current (amp);
h: current efficiency (90–100%).

The rates at which metal can electrochemically remove are in proportion to

the current passed through the electrolyte and the elapsed time for that
operation. Many factors other than current influence the rate of machining.
These involve electrolyte type, rate of electrolyte flow, and some other process
conditions.

Parts made by ECM

Advantages of ECM
• The components are not subject to either thermal or mechanical stress.
• No tool wear during ECM process.
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• Fragile parts can be machined easily as there is no stress involved.
• ECM deburring can debur difficult to access areas of parts.
• High surface finish (up to 25 µm in) can be achieved by ECM process.
• Complex geometrical shapes in high-strength materials particularly in the
aerospace industry for the mass production of turbine blades, jet-engine parts
and nozzles can be machined repeatedly and accurately.
• Deep holes can be made by this process.

Limitations of ECM
• ECM is not suitable to produce sharp square corners or flat bottoms because
of the tendency for the electrolyte to erode away sharp profiles.
• ECM can be applied to most metals but, due to the high equipment costs, is
usually used primarily for highly specialised applications.

Material removal rate, MRR, in electrochemical machining:

MRR = C .I. h (cm 3/min)
C: specific (material) removal rate (e.g., 0.2052 cm 3/amp-min for nickel);
I: current (amp);
h: current efficiency (90–100%).

The rates at which metal can electrochemically remove are in proportion to

the current passed through the electrolyte and the elapsed time for that
operation. Many factors other than current influence the rate of machining.
These involve electrolyte type, rate of electrolyte flow, and some other process
conditions.

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 CHEMICAL MACHINING (CHM)
INTRODUCTION
Chemical machining (CM) is the controlled dissolution of workpiece materia l
(etching) by means of a strong chemical reagent (etchant). In CM material is
removed from selected areas of workpiece by immersing it in a chemica l
reagents or etchants; such as acids and alkaline solutions. Material is removed
by microscopic electrochemical cell action, as occurs in corrosion or chemica l
dissolution of a metal. This controlled chemical dissolution will simultaneously
etch all exposed surfaces even though the penetration rates of the material
removal may be only 0.0025–0.1 mm/min. The basic process takes many
forms: chemical milling of pockets, contours, overall metal removal, chemica l
blanking for etching through thin sheets; photochemical machining (pcm) for
etching by using of photosensitive resists in microelectronics; chemical or
electrochemical polishing where weak chemical reagents are used (sometimes
with remote electric assist) for polishing or deburring and chemical jet
machining where a single chemically active jet is used. A schematic of
chemical machining process is shown in Figure.

(a) Schematic of chemical machining process (b) Stages in producing a

profiled cavity by chemical machining (Kalpakjain & Schmid)

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The chemical machining processes include those wherein material removal
is accomplished by a chemical reaction, sometimes assisted by electrical or
thermal energy applications.

This group includes chemical milling, photochemical machining, and thermo

chemical machining.
 Chemical machining is a well known nontraditional machining process is
the controlled chemical dissolution of the machined workpiece material
by contact with a strong acidic or alkaline chemical reagent.
 Special coatings called maskants protect areas from which the metal is
not to be removed.
 The process is used to produce pockets and contours and to remove
materials from parts having a high strength-to-weight ratio.
 Chemical machining method may be the oldest nontraditional machining
method which is used to shape copper with citric acid in the Ancient Egypt
in 2300 BC
 There are several factors contributing to the popularity of chemical
machining processes as follow
1) Chemical machining process is mature and well established.
2) It is simple to implement.
3) There is no additional cleaning step needed.
4) Cheaper machining process.

CHEMICAL MILLING
In chemical milling, shallow cavities are produced on plates, sheets, forgings
and extrusions. The two key materials used in chemical milling process are
etchant and maskant. Etchants are acid or alkaline solutions maintained
within controlled ranges of chemical composition and temperature. Maskants

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are specially designed elastomeric products that are hand strippable and
chemically resistant to the harsh etchants.

Steps in chemical milling

• Residual stress relieving: If the part to be machined has residual stresses
from the previous processing, these stresses first should be relieved in
order to prevent warping after chemical milling.
• Preparing: The surfaces are degreased and cleaned thoroughly to ensure
both good adhesion of the masking material and the uniform material
removal.
• Masking: Masking material is applied (coating or protecting areas not
to be etched).
• Etching: The exposed surfaces are machined chemically with etchants.
• Demasking: After machining, the parts should be washed thoroughly to
prevent further reactions with or exposure to any etchant residues. Then
the rest of the masking material is removed and the part is cleaned and
inspected.

Applications:
Chemical milling is used in the aerospace industry to remove shallow layers of
material from large aircraft components missile skin panels (Figure ),
extruded parts for airframes.

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 Figure : Missile skin-panel section contoured by chemical milling to improve
the stiffness- to- weight ratio of the part (Kalpakjain & Schmid)

Advantages of chemical machining

The application of chemical machining provides several advantages as follow.

1. Easy weight reduction.

2. No effect of workpiece materials properties such as hardness.
3. Simultaneous material removal operation.
4. No burr formation.
5. No stress introduction to the workpiece.
6. Low capital cost of equipment.
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7. Requirement of less skilled worker.
8. Low tooling costs.
9. The good surface quality.
10. Using decorative part production.
11. Low scrap rates (3%).

Disadvantages of chemical machining

Chemical machining has also some disadvantages

1. Difficult to get sharp corner.
2. Difficult to chemically machine thick material (limit is depended on
workpiece material, but the thickness should be around maximum 10
mm).
3. Scribing accuracy is very limited, causes less dimensional accuracy.
4. Etchants are very dangerous for workers.
5. Etchant disposals are very expensive.

FREQUENTLY ASKED QUESTIONS:

ELECTROCHEMICAL MACHINING (ECM):

1. Mention advantages and disadvantages of Electrochemical machining

(ECM).
2. Mention the applications of Electrochemical machining (ECM).
3. With a neat sketch explain Electrochemical grinding process (ECG).
4. With a neat sketch explain Electrochemical honing process (ECH).
5. Mention the advantages, disadvantages and applications of
Electrochemical grinding process (ECG).
6. Mention the advantages, disadvantages and applications of
Electrochemical honing process (ECH).

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 7. Describe various process parameters affecting ECM. (10 Marks) (VTU
June/July 2011)
8. Calculate MRR and electrode feed rate in an ECM of iron (Fe) that has
a cross sectional area of 25x25 mm with NaCl in water as electrolyte.
The gap between the tool and work piece is 0.25mm. the supply voltage
isweight
12 VDCofand
ironspecific
55.85, resistance
valence = of2; electrolyte is 3 cm.
density 7.87xͳͲ gm/giveଷ .the
(7 atomic
Marks)
(VTU June/July 2011)
9. Differentiate between “fludging” and “non-fludging” electrolyte. (3
Marks) (VTU June/July 2011)
10.Explain with a neat diagram, electrochemical machining process. (6
Marks) (VTU Dec 2011)
11. With a neat schematic diagram, explain the electrochemical honing
process. (8 Marks) (VTU Dec 2011)
12. Explain the advantages and limitations of ECM. (6 Marks) (VTU Dec
2011)
13. With a neat sketch, explain the working principle of ECM process. (8
Marks) (VTU June 2012)
14. Sketch and explain different types of tools used in ECM process. (6
Marks) (VTU June 2012)
15. List the advantages, limitations and applications of ECM process. (6
Marks) (VTU June 2012)
16. Explain ECM with the schematic diagram. (5 Marks) (VTU Dec 2012)
17. Explain functions of electrolytes used in ECM and name 3 electrolytes
with their specialities. (5 Marks) (VTU Dec 2012)
18. Explain chemistry of ECM with the circuit. (5 Marks) (VTU Dec 2012)
19. Theoretically estimate metal removal rate and electrode feed rate of
ECM. (5 Marks) (VTU Dec 2012)
20. With suitable sketches. Explain the metal removal mechanism in
electro chemical grinding. (8 Marks) (VTU June/July 2013)
21. Why are chemical machining and electro chemical machining
considered as chipless machining? Explain the mechanisms of metal

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 removal on both cases and compare it with conventional grinding
process. (12 Marks) (VTU June/July 2013)
22. Explain different elements of electrochemical machining process.
(6 Marks) (VTU June/July 2014)
23. Explain with sketch the electrochemical grinding operation. (6
Marks) (VTU June/July 2014)
24. Calculate the machining rate and the electrode feed rate when
iron is electrochemically machined using copper electrode and sodium
chloride solution. The following data are given as:
Specific resistance of NaCl = 5 ohm cm
Supply voltage = 18 V.D.C
Current = 5000 amp
Tool-work gap = 0.5mm
Current efficiency = 100%
Atomic weight of iron, N = 56
Valency of iron, n = 2
Density, d = 7.87x / (8 Marks) (VTU June/July 2014)
25. What are the advantages and disadvantages of ECM? (6 Marks)
(VTU Dec 2014/Jan 2015)
26. What are the factors that influences oxidation of ECM? (4 Marks)
(VTU Dec 2014/Jan 2015)
Explain the principle of electro chemical grinding, with a neat sketch.
(10 Marks) (VTU Dec 2014/Jan 2015)
27. Explain the chemistry of ECM process with diagram. (8 Marks)
(VTU June/July 2015)
28. List the functions of electrolyte in ECM process. (8 Marks) (VTU
June/July 2015)
29. Explain with diagram, working of electro chemical grinding (ECG).
(8 Marks) (VTU June/July 2015)
30. Draw schematic sketch of electro chemical machining and explain
briefly the elements of ECM process. (10 Marks) (VTU June/July 2016)
31. Explain with neat schematic diagram of electro chemical grinding and
their advantages and application. (10 Marks) (VTU June/July 2016)
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CHEMICAL MACHINING (CHM):

1. Mention advantages and disadvantages of Chemical machining (CHM).

2. Mention the applications of Chemical machining (CHM).
3. Discuss the factors to be considered for selection of ‘Maskants’ and the
types that are used in ‘chemical machining’. (10 Marks) (VTU June/July
2011)
4. Differentiate between ‘chemical milling’ and chemical blanking’. (4
Marks) (VTU June/July 2011)
5. Write a note on ‘etchants’ in ‘chemical milling’. (6 Marks) (VTU June/July
2011)
6. What is chemical machining? Explain briefly the elements of the process.
(7 Marks) (VTU Dec 2011)
7. Explain briefly, the chemical milling process with the help of neat flow
chart. (7 Marks) (VTU Dec 2011)
8. Discuss the advantages and applications of CHM. (6 Marks) (VTU Dec
2011)
9. What are Maskants used in chemical machining? Explain the different
types of it. (10 Marks) (VTU June 2012)
10.What are the factors to be considered in the selection of etchant? (4
Marks) (VTU June 2012)
11. Explain the chemical blanking process stepwise with the flow chart. (10
Marks) (VTU Dec 2012)
12. Write a note on etchants indicating factors to select. (6 Marks) (VTU
Dec 2012)
13. Write advantages of chemical machining. (4 Marks) (VTU Dec 2012)
14. Explain in brief the following in chemical machining process:
i) Maskants.
ii) Etchants. (8 Marks) (VTU June/July 2013)
15. With the help of neat sketches. Explain the different steps involved in
chemical blanking. (12 Marks) (VTU June/July 2013)
16. Explain with flow chart the chemical blanking process. Mention its
applications. (10 Marks) (VTU June/July 2014)
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 17. Explain with flow chart the chemical milling process. Mention its
advantages and applications. (10 Marks) (VTU June/July 2014)
18. Explain the principle steps involved in chemical milling to produce
pockets and contours. (6 Marks) (VTU Dec 2014 / Jan 2015)
19. List out the advantages and disadvantages of chemical machining. (8
Marks) (VTU Dec 2014 / Jan 2015)
20. List out the major applications of CHM. Further process
application related to improving the characteristics. (6 Marks) (VTU
Dec 2014 / Jan 2015)
21. Explain the elements of chemical machining process. (6 Marks) (VTU
June/July 2015)
22. Explain with flow chart the chemical blanking process. (10
Marks) (VTU June/July 2015)
23. Mention the limitations of chemical machining process. (4 Marks)
(VTU June/July 2015)
24. What are the factors on which the selection of a resist for all in
chemical machining depend? (3 Marks) (VTU June/July 2016)
25. Explain the elements of process
(i) Maskants or resist.
(ii) Etchants in CHM. (8 Marks) (VTU June/July 2016)
26. Explain with sketch progressive stages of metal removal in
chemical blanking. (6 Marks) (VTU June/July 2016)
27. List the applications of chemical machining. (3 Marks) (VTU
June/July 2015)

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