Electrochemical Machining ECM

Dependent on current density, electrolyte and gap between tool and workpiece. High power consumption. 

Lead time can be several weeks. Tools are very complex. 

Material utilization very poor. Scrap material cannot be recycled. 

Disposal of sludge and chemicals used can be costly and hazardous. 

Tooling costs very high. Dedicated tooling. 

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The electrochemical machining (ECM) of metals rests on the selective local anodic dissolution of metal. It is used to give metal parts the required shape and size, to drill holes, create hollows, cut shaped slots, and fashion parts of a complex pattern (e.g., the blades of gas turbines). It is an advantage of this method that it can also be used for hard metals (high-alloy steels and other alloys, metals in the quenched state, etc.). 

Electrochemical gas sensor, 13 589 Electrochemical grinding, 9 603 Electrochemical machining (ECM), 9 590-606... 

Ultrasonic machining (USM) is also of particular importance when very hard type materials are to be cut. As an assist to drilling, HDM energy can extend the drill life when producing holes in reinforced plastics. If the plastic is conductive, electrical discharge machining (EDM) or electrochemical machining (ECM) may be useful. 

Electrochemical machining (ECM) is a method of metal machining that aims at producing parts of specified shape, dimensions, and surface finish. The process is based on the removal of metal by electrochemical dissolution ([1-15] and references cited therein). Special machines have been developed to realize this aim. A complete ECM installation (Fig. 1) consists of the machine, the power supply, the electrolyte circulation system (tank, pump, heat exchanger, and sludge removal unit), and the control system (control of current, voltage, feed rate, gap width, and electrolyte temperature, pH value, pressure, and concentration short-circuit protection). 

An important characteristic of the process of electrochemical machining (ECM) is that it runs with rather high current densities. An order of magnitude is 50-150 A/cm. For example, under this condition the removal rate of iron is about 1.2 mm/min and a distance of 0.4 mm between anode and cathode is a typical value. 

For electrochemical machining (ECM) there are two possibilities. When the steady-state gap h is equal... 

Electrochemical machining (ECM) is a material removal process into which pulsed current is dissipated through a conductive electrolytic solution between the tool and the workpiece (Fig. 2). Such chemical interaction causes material to be removed from the workpiece according to the shape of the tool. ECM is based on thermal effects by extremely quick heating, melting, and vaporizing. The heat sources are the energy... 

Electrochemical machining (ECM) is a metal removal process based on the laws of electrolysis. The need for ECM has stemmed from the recent development of high-strength heat-resistant alloys which are difficult to machine by conventional techniques. 

Electrochemical machining (ECM) relies upon a high local current density and control of the anodic dissolution such that passivation (Chapter 10) does not... 

Probably the most widely used of these methods for titanium and titanixim alloys are electrochemical machining (ECM), chemical milHng (CHM), and laser-beam machining (LBM). 

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