ELECTROCHEMICAL

MACHINING (ECG, ECD,

ECH)
by:
Mr. Abhijeet B. Chougule
Assistant Professor,
Mechanical Engineering Department,
RIT, Rajaramnagar
 Electro-Chemical Grinding
Electro-chemical grinding (ECG) is a variant process of the basic ECM. It is a burr free and stress free material
removal process, wherein material removal of the electrically conductive material takes place through mechanical
(grinding) process and electro-chemical process.

• The abrasive laden grinding wheel is negatively charged and the workpiece is positively charged.
• They are separated by an electrolyte fluid.

Electrochemical grinding and electrochemical machining are similar processes with a difference that a wheel
substitutes the tool used in ECM. The wheel shape is similar to the desired work shape.
PROCESS OF GRINDING IN ECM
• The main feature of electrochemical grinding (ECG) process is the use of a metallic grinding wheel which is
embedded with insulating abrasive particles such as diamond, set in the conducting material.

• Copper, brass, and nickel are the most commonly used materials while aluminum oxide is a typical abrasive used
while grinding steels.

• The commutator is an electrolytic spindle having carbon brushes and holds the grinding wheel. It receives a
negative charge from the DC power supply and the workpiece is given a positive charge.

• The grinding wheel slightly touches the workpiece.

• Electrolyte is supplied on-to the grinding wheel (Nozzles) near the workpiece such that the wheel carries it
through the cutting process thereby resulting in an electro-chemical action.
PROCESS CHARACTERISTICS

• The life of grinding wheel in ECG process is very high as around 90% of the metal is removed by electrolysis
action and only 10% is due to the abrasive action of the grinding wheel.
• The ECG process is capable of producing very smooth and burr free edges unlike those formed during the
conventional grinding process (mechanical).
• The heat produced in the ECG process is much less, leading to lesser distortion of the workpiece.
• The major material removal activity in ECG process occurs by the dissolving action through the chemical process.
There is very little tool and workpiece contact and this is ideally suited for grinding of the following categories:
• Fragile work-pieces which otherwise are very difficult to grind by the conventional process
• The parts that cannot withstand thermal damages and
• The parts designed for stress and burr free applications.
APPLICATIONS

The applications of ECG process include the following:

• In production of tungsten carbide cutting tools.
• In burr-free sharpening of hypodermic needles.
• In grinding of super-alloy turbine blades.
• In form grinding of aerospace honeycomb metals.
• In removal of fatigue cracks from steel structures that have been used for
• underwater applications.
ELECTRO CHEMICAL HONING
Electro Chemical Honing process comes under the process of Electro Chemical Machining process. It is the usage of combined
power of electricity and chemical energy for the material removal from the work piece is known as Electro Chemical Machining
process. Now lets know about Electro Chemical Honing process. Electro Chemical Honing process is mostly employed for better
surface finish, accuracy and economic aspects too.

An Electro Chemical Honing Process consists of a tool, non conducting abrasive honing stones, cylinder and an electrolyte. It has
a negative pole, a positive pole, electrolyte and a tool.

In this process, the tool inside the cylindrical parts moves in the longitudinal as well as rotational direction. To obtain uniform
flow, the electrolyte is feeded to the tool under pressure through the holes. The abrasive honing stones are pushed forward to
move in the slots under equal pressure in all directions. These stones help to assist the electrochemical action and also to scratch
the left over unfinished surfaces. Thus, a clean finished surface is obtained. If the shape of the work piece is tapered or wavy, the
stones cut all the high areas and eliminate the geometric error.
ELECTROCHEMICAL HONING
The surface finish of the electrochemical honing process obtained is mostly based up on the following terms:-

1. Size of the abrasive grains.

2. Speed of the rotation and reciprocation.
3. Duration of the run out period.
ADVANTAGES OF ELECTO CHEMICAL HONING PROCESS-

1.Electro Chemical Honing process enhances the material removal rate specifically for harder materials.
2. There is no presence of burrs on the finished surfaces.
3. Electro Chemical Honing process requires minimum amount of work pressure on the tool and the work piece.
4. Electro Chemical Honing process reduces the noise level and distortion while honing thin walled tubes.
5. Electro Chemical Honing process increases the accuracy without damaging the materials due to the provision
of cooling medium.

APPLICATIONS OF ELECTRO CHEMICAL HONING PROCESS-

1. Electro Chemical Honing process is used for machining small size materials with greater accuracy.
2. Electro Chemical Honing process is applicable for the cylindrical components where truing operation is
performed on the interior surfaces.
ELECTRO CHEMICAL DEBURRING:
Manufacturing high-precision surfaces and deburring in an efficient manner with minimal workpiece finishing time is a
primary objective of manufacturing engineers working in fields such as aerospace, transportation and energy.

Components that have intricate shapes with very low finishing tolerances are often needed. The effects of component stress
as a result of the manufacturing process are also a concern for components that will be functioning under extreme operating
conditions.
Electrochemical deburring is a method that finishes the workpiece surfaces by means of anodic metal dissolution. The
deburring tool is the cathode (-) that acts under DC current and in the presence of an electrolyte fluid to create the anodic
reaction that removes workpiece (+) surface material in a precise manner.
ECM DEBURRING PROCESS WORKS:

•The electrolyte solution transfers charge in the gap between the cathode and workpiece, which causes electron
transfer from the workpiece to remove surface material.
•The separation distance between the cathode and the workpiece is key to regulating the material removal
process.
•The shape of the cathode determines the final shape of the workpiece or the impression (imaging) placed
upon the workpiece.
•The speed of material removal is dictated by the DC current applied.
•The amount of material removed is defined by Faraday’s Laws.
•The material removed during the deburring process must be filtered out of the electrolyte stream in order to
maintain constant electrolyte quality in the gap between the cathode and the workpiece.
•The workpiece material must be corrosion resistant.