 
Electrochemical
Machining Set-up
|
|
|
|
|
|
Electrochemical
Machining Set-up
EC MAC- II |
|
-
Non
conventional machining process
-
Universal
set-up demonstrating many aspects
-
Years
of experience
-
First
time in the world, for educational field
|
 |
Top
About
ECM
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.
Top |
Various
Aspects covered
One can study
various aspects with investigative experiments by this single set-up.
-
Demonstration
of the process.
-
Comparison
of theoretical and observed Metal Removal Rates ( M.R.R.).
-
Accuracy and
over cut produced at different feed rates, voltage etc.
-
Surface
Finish in ECM.
-
Machining
large area quickly.
-
Tool design.
-
Machining
odd shapes.
-
Embossing.
-
Machining of
metals difficult to machine by conventional methods.
There are many
other experiments possible depending upon ingenuity of user.
Top |
Machining process
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.
Top
|
Construction
The set up
consists of three major sub systems
1. Machining Cell
2. Control Panel
3. Electrolyte Circulation
Machining Cell
This electro-mechanical
assembly is a sturdy structure, associated with precision
machined components, servo motorised vertical up /
down movement of tool, an electrolyte dispensing
arrangement, illuminated machining chamber with see through
window, job fixing vice, job table lifting mechanism and
sturdy stand. All the exposed components, parts have
undergone proper material selection and coating / plating
for corrosion protection.
Technical
Data
- Tool area - 30 mm2.
- Cross head stroke - 150 mm.
- Job holder - 100 mm opening X
50 mm depth X 100 mm width.
- Tool Feed motor - DC Servo
type.
|


|
Control Panel
The power supply is a
perfect integration of, high current electrical, power electronics
and precision programmable microcontroller based technologies.
Since the machine operates at very low voltage, there are no
chances of any electrical shocks during operation.
Technical
Data
-
Electrical
Out Put Rating - 0-300 Amps.DC at any
voltage from 0 - 20 V.
-
Efficiency
- Better than 80% at partial & full load
condition.
-
Power
Factor - Better than 85.
-
Protections
- Over load , Short circuit, Single phasing.
-
Operation
Modes - Manual / Automatic.
-
Timer
- 0 - 99.9 min.
-
Tool
Feed - 0.2 to 2 mm / min.
-
Z
Axis Control - Forward , reverse , auto forward /
reverse, through micro controller.
-
Supply
- 415 v +/- 10%, 3 phase AC, 50 Hz.
|

|
Electrolyte
Circulation
The electrolyte is pumped
from a tank, lined by corrosion resistant coating with the
help of corrosion resistant pump & is fed to the job.
Spent electrolyte will return to the tank. The hydroxide
sludge arising will settle at the bottom of the tank &
can be easily drained out. Electrolyte supply shall be
governed by flow control valve. Extra electrolyte flow is
by- passed to the tank. Reservoir provides separate settling
and siphoning compartments. All fittings are of
corrosion resistant material or of S.S., as necessary.
|

|
Top
|
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)
Top
|
Tool
( Electrode )
Tool
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.
|
 |
 |
 |
 |
Top
|
Working
Manual
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
Top
Industrial
Set-ups
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 .
Top
|