electrolytic rifling solutions

the inside edge

SM
 The ECR process typically results in excellent surface finish
The advantages of
in the grooves (16 µin Ra / 0.4µm Ra or better) without
electrochemical rifling
machining marks such as those caused by broaches. Stress Free Rifling.
Since the conductive groove machining elements on the Metal is 100% removed by electrolytic
tool (cathodes) do not contact the bore surface, there is action with no cutting, swaging or
no mechanical wear and repeatable accuracy is excellent. displacing of material.
Repeatable accuracy of 0.0003 inch (0.075 mm) is typical.
The process time is also excellent with tool traverse speed Full Selection of Groove Geometry.
of 5 to 15 inches per minute (200 to 600 mm per minute). The ECR process can produce
polygonal and many other forms
ECR Broached Land to of groove geometry.
groove
transition Any Metal and Alloy.
of ECR vs The ECR process quality does not vary
broached with the mechanical strength of the
barrel material and is used to rifle many
Electrolytic Machining and Rifling (ECR) alloys such as Titanium, Stellite, etc.

Electrolytic Rifling (ECR) is an electrochemical process used to produce Burr Free Rifling.
a wide range of rifling groove configurations in barrels and choke tubes There are no burrs or tool marks
of almost any length or diameter. Our Electrolytic Rifling process can left on the surface.
produce constant or gain twist grooves in almost any conductive metal Excellent Tool Life. Electrochemical
(including high end alloys such as Stellite). process results in material removal
The ECR process consists of a machining tool (called a cathode) from the positively charged barrel
configured to the desired rifling geometry that is driven through a (anode) only, hence wear only occurs
ECR has a number of unique aspects… on the tool guides which can last for
barrel at a predetermined speed and rotation. Non metallic guides • Grooves have radiused sides as contrasted to the
on the tool hold brass conductive groove machining elements a short over 1,000 barrels.
more square corners produced by other methods
distance from the bore surface and masks the land surface from as depicted in the illustration (it has been noted that Finish and Accuracy.
machining current. An electrolyte—typically a solution of salt and ECR groove contour is comparable to or better than The ECR process will consistently
water—is constantly pumped through the gap between the conductive a broached barrel which has subsequently been produce a high quality finish
groove machining elements and the bore surface. As the tool traverses electro-polished and plated) and repeatable accuracy.
through the barrel, a Direct Current (DC) voltage applied to the tool (–)
and the barrel (+), results in a current that conducts through the electrolyte • ECR machining rates on materials such as stainless Thinner Gauge Blanks.
and produces electrochemical material removal of the exposed bore steel are as fast as on conventional barrel material, ECR can be applied to barrels with
surface immediately adjacent to the conductive
c groove machining elements. with no increase in tool wear (and produces a better very thin walls. No extra thickness
The groove depth is controlled by the amount of current that flows surface finish than other methods) or barrel length is needed.
between the barrel and tool.
• The cathode tools are much less expensive than High Productivity.
tools for other methods The ECR process is as fast as (and in
some cases faster than) hammer forging,
Other aspects of ECR include the ability to produce broaching and cut rifling.
polygonal and other non-standard rifling forms at the
same production rates and surface quality as standard Achievable results:
ECR rifling. Also, since ECR tools move through the bore Feed Rate – 3” to 15” per minute
during the process it is possible to machine progressive (depending on size, material,
groove depths by controlling the machining current. groove depth, etc.)
Cycle time – as short as 10 to 15 seconds.
ECR is a cost-effective alternative to broaching from
and hammer forged rifling. Examination of barrels .17 cal Gain Twist. The ECR process can
produced by ECR reveals high-quality grooves free up to produce gain twist as easy as constant
from tool marks and tool related stresses (ECR barrels 40 mm twist and progressive depth of grooves
The Electrolytic Rifling process
do not require stress-relieving) and accuracy is equal is also possible.
is accurate and reliable which results
to or better than traditionally-manufactured bores.
in consistent part quality. Current ECR Capabilities:
.17 cal to 40 mm
 electrolytic rifling solutions

Typical ECR machine for pistols and shorter barrels

Extrude Hone Corporation provides many

solutions to the firearms industry, including;

• rifling of barrels and choke tubes

using the Electrolytic process (ECR)

• smoothing and blending of barrels

and cylinder chambers with Abrasive
Flow Machining (AFM)

• deburring and deflashing metal

components with the
Thermal Energy Method (TEM)

These unique machining, deburring, and

finishing technologies provide increased value
to the components through increased strength, High-production
accuracy, appearance, and usability. To find out more Abrasive Flow Machining system
about these processes and production equipment for for polishing gun barrels
your facility or contract services from our facility,
contact Extrude Hone.
The Inside Edge, Extrude Hone, SurfTran, and Dynetics are trademarks and/or service
marks of Extrude Hone Corporation and/or its subsidiaries.

©2004 Extrude Hone Corporation

firearms solutions 002—feb2004

EXTRUDE HONE EXTRUDE HONE CATION EXTRUDE HONE EXTRUDE HONE GmbH EXTRUDE HONE Far East
Corporation SurfTran A Subsidiary of Dynetics Berghauser Str. 62 Shinwa 3-137-2
1 Industry Boulevard 30250 Stephenson Highway EXTRUDE HONE 30 Nashua Street D-42859 Remscheid Misato-shi

the inside edge

P. O. Box 1000 Madison Heights, MI 48071 2341 Alger Street Woburn, MA 01801 Germany Saitama 341-0034 SM
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