Non-traditional Machining Processes
Abrasive Flow Machinging - (AFM) Chemical Machining Chemical Milling Electrical Discharge Grinding (EDG) Electrical Discharge Machining (EDM) Electrochemical Discharge Grinding (ECDG) Electrochemical Grinding (ECG) Electrochemical Honing (ECH) Electrochemical Machining (ECM) Electrochemical Turning (ECT)	Electron Beam Machining (EBM) Ion Beam Milling - (IBM) Laser Beam Machining - (LBM) Laser Cutting Laser Drilling Photochemical Machining - (PCM) Plasma Arc Machining- (PAM) Ultrasonic Machining WaterJet Machining AbrasiveJet Machining

Electrochemical machining (ECM)

Electrochemical machining (ECM) also uses electrical energy to remove material. An electrolytic cell is created in an electrolyte medium, with the tool as the cathode and the workpiece as the anode. A high-amperage, low-voltage current is used to dissolve the metal and to remove it from the workpiece, which must be electrically conductive. ECM is essentially a deplating process that utilizes the principles of electrolysis. The ECM tool is positioned very close to the workpiece and a low voltage, high amperage DC current is passed between the two via an electrolyte. Material is removed from the workpiece and the flowing electrolyte solution washes the ions away. These ions form metal hydroxides which are removed from the electrolyte solution by centrifugal separation. Both the electrolyte and the metal sludge are then recycled.

Unlike traditional cutting methods, workpiece hardness is not a factor, making ECM suitable for difficult-to-machine materials. Takes such forms as electrochemical grinding, electrochemical honing and electrochemical turning.

Electrochemical deburring is another variation on electrochemical machining designed to remove burrs and impart small radii to corners. The process normally uses a specially shaped electrode to carefully control the process to a specific area. The process will work on material regardless of hardness.

 

Advantages of Electrochemical Machining (ECM)

1. The components are not subject to either thermal or mechanical stress.
2. There is no tool wear during Electrochemical machining.
3. Non-rigid and open work pieces can be machined easily as there is no contact between the tool and workpiece.
4. Complex geometrical shapes can be machined repeatedly and accurately
5. Electrochemical machining is a time saving process when compared with conventional machining
6. During drilling, deep holes can be made or several holes at once.
7. ECM deburring can debur difficult to access areas of parts.
8. Fragile parts which cannot take more loads and also brittle material which tend to develop cracks during machining can be machined easily through Electrochemical machining
9. Surface finishes of 25 µ in. can be achieved during Electrochemical machining