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Electrochemical Machining Set-up |
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Electrochemical
Machining Set-up
EC MAC- II
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Non conventional machining process
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Universal set-up demonstrating many aspects
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Years of experience
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First time in the world, for educational field
Electrochemical
Machining (ECM) is the controlled removal of metal by anodic dissolution
in an electrolytic cell in which the workpiece is the anode and the tool
is cathode. The electrolyte is pumped through the gap between the tool and
the workpiece, while direct current is passed through the cell, to
dissolve metal from the work piece.
ECM is widely used in machining of jobs involving intricate shapes and to
machine very hard or tough materials those are difficult or impossible to
machine by conventional machining. It is now routinely used for the
machining of aerospace components, critical deburring, Fuel injection
system components, ordnance components etc. ECM is also most suitable for
manufacturing various types of dies and moulds.
For the first time ECM is developed for educational institutions, after
years of experience and expertise demonstrating various aspects of
electrochemical machining technology. The set up has robust construction,
reliable and sophisticated technology, user friendly operation and is easy
for maintenance. Extra care is taken while designing for operator safety
by providing various protections.
One can study various aspects with investigative experiments by this single set-up.
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Demonstration of the process.
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Comparison of theoretical and observed Metal Removal Rates ( M.R.R.).
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Accuracy and over cut produced at different feed rates, voltage etc.
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Surface Finish in ECM.
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Machining large area quickly.
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Tool design.
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Machining odd shapes.
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Embossing.
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Machining of metals difficult to machine by conventional methods.
There are many other experiments possible depending upon ingenuity of user.
The
job to be machined is fixed in the vice, in the machining chamber, that is
sealed for any leakage of electrolyte and is corrosion resistant, having
window to see machining operation. Tool is brought near the job with the
help of press buttons provided on the control panel and table lifting
arrangement, maintaining particular gap. The tool progress is manoeuvred
vertically by servo motor and is governed by micro controller based
programmable drive. Then the process parameters are set like tool feed
rate, voltage, timer, auto/manual mode, etc.
The process is started in the presence of an electrolyte flow that is
circulated with the help of special pump filling the gap between anode (
job ) and cathode ( tool ). Electrolyte flow is adjusted by flow control
valve. The machining is achieved by sinking of tool forming its replica.
During the operation sophisticated control panel takes care of any damage
to the machine by over load and short circuit protections. After desired
time interval hooter gives an indication of completion of the time /
process. The small machining area with given power supply an be machined
within 30 mins. to one hour.
Construction
The set up
consists of three major sub systems
1. Machining Cell
2. Control Panel
3. Electrolyte Circulation
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Technical Data
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Technical Data
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Electrolyte and reaction
Electrolyte has three main functions in ECM : It carries the current between the tool and work piece; it removes the products of the reaction from the cutting region; and it removes heat produced in operation. Normal electrolyte used for ECM for all common metals & alloys is solution of Sodium Chloride (NaCl) in water. When supply is switched on, the negative ions Cl migrate towards the anode. They react with the work piece and form a salt which dissolves in electrolyte. Thus if a job is steel (Fe) and electrolyte is common salt ( NaCl ) the following reacting takes place at the anode. NaCl -> Nacl +Cl (Dissociation), Fe+(n) Cl Fe Cl n (Machining)
Tool ( Electrode )
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design for electrochemical machining is a subject by itself. In
ECM generally tool which is cathode, is made out of non reacting
material such as Copper. |
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This shall consists of details on various experiments that can be conducted, operational details, parameters to set, electrical /electronics circuit diagrams, technical data on electrolytes; trouble shooting; faults and remedies. Working manual
Industrial systems can also be developed pertaining to specific jobs manufacturing requirements like Dies manufacturing, Critical deburring, Gun barrel machining, Nozzle cleaning, Air Bag, Antilock break systems components, Fuel injection system parts, Hydraulic Components, Pneumatic Components, ABS Parts, Transmission Parts, Aerospace components, Medical components, Firearms & Ordnance components etc. and many such more .