This process is used to machine only conductive materials. Table of Contents. Process Parameter S. Surface roughness Ra. Related Posts: What is Heat Exchanger? What is Atomic Hydrogen Welding? Leave a Comment Cancel Reply Your email address will not be published. Power Supply. Direct Current. Current Density. NaCl and NaNO3. The power supply also includes a protective device for OFF in the event of tool getting too close to the workpiece, or failure of electrolyte supply, or supply of improperly filtered electrolyte.
Since the filters get clogged with small particles of grit and products of machining, they need to be cleaned once in 30 Figure 5: Electro chemical machining hours. Alternately, a centrifuge separator can be used for the 3. As machining proceeds, and with the deformed materials may be machined in thin walled simultaneous movement of the cathode at a typical rate, for shapes. Under these conditions, a shape, roughly complementary to The wheel is conductive and catholically connected.
A typical gap Non-conductive hard particles are set on the wheel width then should be about 0. The particles provide a constant gap through which an electrolyte is continuously fed. Hard and brittle materials are ground by the method. An electrolyte in ECM performs three basic functions, which are as follows: 1 Completing the electrical circuit and allowing the large current to pass.
Figure 6: Electrolyte flow Electrical conductivity of the electrolytes must be high, toxicity and corrosiveness should below.
The electrolyte V. At low current Electrolyte and its concentration densities, metal removal rate is small. The 1. Co-Cr-w Nacl current density. If the feed rate is increased the electrical based resistance of the tool-work gap reduces to allow current to 5. WC based Strong alkaline solution flow resulting in high metal removal rates.
Also, it produces 4. Small gap results in high machining in ECM process. The gap size may vary from 0. A gap Divergent flow size of 0. If the electrolyte flow is too low, the machined hole. Too high velocity will Convergent flow cause cavitations, also promoting non-uniform metal removal. For instance, sodium chloride is cheap and provides good conductivity. However, it is corrosive and hence, cannot be used on tungsten carbide or molybdenum materials. Sodium nitrate is also popular due to its less corrosive nature.
But it does not produce a good surface finish as that of sodium chloride. It is preferred for machining aluminum and VI. Low concentrations decrease the equilibrium machining gap resulting in better Electrochemical machining E. Electrolyte temperature complicated processes, because of the numerous seriously affects the overcut. The power loss in electrolyte interconnected machining parameters. This work is directed reaction gives rise to an increase in the temperature of the towards the determination of the optimum operating electrolyte.
The heat must be carried away from the cutting parameters; this process is based on certain economic area so as to maintain stable and steady conditions.
Low machining criteria. The economic success of ECM Hence no tool wears depends largely on the choice of applications. Soft materials e. It can handle make many cavities simultaneously any electrochemically reactive material. Hence, no thermal effects on the workpiece. The sludge abrasive particles grinding on the work material. In this technique, the workpiece plays the role of the anode while the grinding wheel works as a cathode. The tool is rotated and reciprocated on a rigid spindle for precise metal 8.
The length of the stones is selected to be approximately one-half the length of the bore being processed. The 8. The electrolyte is pumped to the work region by the pump via a filter, pressure gauge, flow meter and finally, it enters into the work region from the passage.
When the Power supply is given, an optimum gap is maintained between the tool and workpiece because of Faraday's laws of electrolysis, the ions have started displacing from the workpiece and trying to deposit over the tool.
Before the ions are depositing on the tool, the electrolyte present between tool and workpiece is pumped out. Then, the ions also moving along with electrolyte without depositing on the tool. From the above, the mechanism of material removal is Ion displacement and because there is no disturbance taking place in the tool, the same tool can be used for producing an infinite number of components. This is the detailed explanation of the electrochemical machining process along with the basic terms and working.
This is the explanation of Electrochemical Machining Process with its advantages, limitations, and applications in a detailed way.
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