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Electrochemical machining (ECM)
This document discusses electrochemical machining (ECM), a non-traditional machining process that removes metal through an electrochemical process. ECM can machine extremely hard materials like titanium or carbide by acting as the cathode in an electrolytic cell, while the workpiece acts as the anode. Metal is removed from the workpiece as an electric current flows between the two electrodes in an electrolyte like salt water. ECM allows for intricate internal and external geometries to be machined and is capable of machining hard metals that other methods struggle with.
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ECM is a non-traditional process to cut hard conductive materials using an electrochemical method.
Electrodes create a potential difference, removing metal via an electrolyte, with removal rate linked to gap size.
Discusses the benefits of ECM including precision machining and ability to work with hard materials.
Highlights the limitations and drawbacks of ECM, including cost and material limitations.
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Electrochemical machining (ECM)
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- 2. INTRODUCTION Electrochemical machiningis a method of removing metal by an electrochemical process. It is a non-traditional machining process belonging to the electrochemical category. It is used for machining extremely hard materials or materials that are difficult to machine using conventional methods. Its use is limited to electrically conductive materials. The process has the capabilities of machining or cutting the intricate contours or cavities in hard steel such as titanium, Hastelloy, Kovar, Inconel, and Carbide. External as well as internal geometries can be machined with an electrochemical machine.
- 3. MECHANISM OF MATERIALREMOVAL IN ECM The workpiece and tool are the anode and cathode respectively. In the electrolytic cell a constant potential difference, usually of about 10 V is applied across them. A suitable electrolyte, for example an aqueous sodium chloride (table salt) solution is commonly chosen. In-order to remove the products of machining, the electrolyte is pumped through the gap between the two electrodes. The rate at which metal is then removed from the anode is approximately in inverse proportion to the distance between the electrodes. As the machining proceeds there is a simultaneous movement of the cathode towards the anode. The width of the gap along the electrode length will gradually tend towards a steady-state value. Under such conditions, a shape which is roughly complementary to that of the cathode will be reproduced on the anode.
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