Dhruv Patel (11BIE024) Rajat Patel (11BIE025) Electrochemical Machining • Electrochemical machining (ECM) is a Non-traditional machining process that relies on the removal of work piece atoms by electrochemical dissolution. • The machining current passes through the electrolytic solution that fills the gap between an anodic work piece and a preshaped cathodic tool. • The electrolyte removes the dissolution products, such as metal hydroxides, heat, and gas bubbles, generated in the interelectrode gap. Introduction • Shaped tube electrolytic machining (STEM) is based on the dissolution process when an electric potential difference is imposed between the anodic work piece and a cathodic tool. • Because of the presence of this electric field the electrolyte, often a sulphuric acid, causes the anode surface to be removed. • After the metal ions are dissolved in the solution, they are removed by the electrolyte flow the tool is a conducting cylinder with an insulating coating on the outside and is moved toward the work piece at a certain feed rate while a voltage is applied across the machining gap. In this way a cylindrically shaped hole is obtained. S.T.E.M • STEM is, therefore, a modified variation of the ECM that uses acidic electrolytes. • The process is capable of producing small holes with diameters of 0.76 to 1.62 mm and a depth-to-diameter ratio of 180:1 in electrically conductive materials. • It is difficult to machine such small holes using normal ECM as the insoluble precipitates produced obstructs the flow path of the electrolyte. Process Parameters • Electrolyte: Type: Sulphuric, Nitric and Hydrochloric Acids Concentration: 10–25% weight in water Temperature: 38°C (sulphuric acid) and 21°C (others) Pressure: 275–500 kPa • Voltage: Forwar0d: 8–14 V Reverse: 0.1–1 times the forward • Time: Forward: 5–7 s Reverse: 25–77 ms • Feed rate: 0.75–3 mm/min Process Capabilities
• Hole size: 0.5-6mm diameter at an aspect ratio of 150
• Hole tolerances: 0.5-mm diameter ± 0.050mm 1.5-mm diameter ± 0.075 mm 60-mm diameter ± 0.100 mm Hole Depth ±0.050 mm Advantages
• The depth-to-diameter ratio can be as high as 300.
• A large number of holes (up to 200) can be drilled in the same run. • Nonparallel holes can be machined. • Blind holes can be drilled. • No recast layer or metallurgical defects are produced. • Shaped and curved holes as well as slots can be produced. Limitations
• The process is used for corrosion-resistant metals.
• STEM is slow if single holes are to be drilled. • A special workplace and environment are required when handling acid. • Hazardous waste is generated. • Complex machining and tooling systems are required. Applications • Because the process uses acid electrolytes, its use is limited to drilling holes in stainless steel or other corrosion-resistant materials in jet engines and gas turbine parts such as: • Turbine blade cooling holes. • Fuel nozzles. • Any holes where EDM recast is not desirable. • Starting holes for wire EDM. • Drilling holes for corrosion-resistant metals of low conventional machinability. • Drilling oil passages in bearings where EDM causes cracks. Thank You!!..