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2010/12/12

Manufacturing Processes - ECM Electrochemical Machining Proc

Electrochemical Machining ECM

Electrochemical Machining fits in the category of machining as a manufacturing process. It involves removal of material from a workpiece using electrolysis. This is achieved by connecting the workpiece and the electrode to an electrical power supply. Similar to electrical discharge machining the material for this process to work has to be electrically conductive, but unlike electrical discharge machining the workpiece and electrode are immersed in an electrolyte fluid as opposed to a dielectric fluid.

Electrochemical Machining Advantages

The main advantage of electrochemical machining is that it can be used to machine extremely hard materials with no stressing. This is due to the absence of physical contact and heat. You will notice that there are many similarities between electrochemical machining ECM and electrical discharge machining EDM and consequently the advantages for both are also very similar, but ECM does have some distinct advantages over EDM.


Advantages over EDM

  • thin section and fragile parts can be machined (no stress involved)
  • its faster than EDM
  • There is no tool wear with ECM, 
  • There is no heat involved
  • Tool can be made from soft electrode materials such as copper which is very easy to machine

Electrochemical Machining Disadvantages

The main disadvantage of electrochemical machining is that the process is not particularly environmentally friendly. Not only is it a high energy process but it also produces a chemical sludge that needs to be disposed of. In addition to that the equipment used has a tendency to become corroded so requires frequent maintenance.

In terms of cost, equipment is also more expensive than standard machinery and equipment.

Electrochemical Machining Process

The process involves removing any electrically conductive material using anodic dissolution of the workpiece in a stream of electrolyte. The electrolyte separates the workpiece which is the positive anode side (+ve) from the tool electrode which is the negative cathode (-ve) side. The feed rate of the tool is then matched to the dissolution rate of the workpiece with removal rate being governed by Faraday's law which in practice means it is limited by the current and the electrolyte used. Features machined into the workpiece are a mirror image of the tool and the quality of the machined finish is inversely proportional to the rate of material removal.

Because there is no tool wear whatsoever, the tool can be made to any required shape out of a soft material such as copper.

It is common practice to load several electrodes into one tool holder in order to machine complex components with multiple cavities. The process can be duplicated very easily due to the fact there is no tool wear. It is a simple case of changing out the workpiece and running the program again. However compared to standard machining the cycle times would be considered quite long, but this is somewhat offset by the faster setting up times involved and the lack of tool wear.


ECM Electrochemical Machining


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本館專門提供 OTEC 表面處理技術皆集中於精密研磨,拋光, deburring, smoothing and polishing. 還有VTD PVD 超硬工具鍍膜 tool coating, 精密光學鍍膜 optical coating, 真空金屬鍍膜 metalization absolute chemie PVD/CVD 退鍍工藝和 EMAG ECM / Precise Electrochemical Machining 精密電化學加工技術, EMAG 硬車削/乾式切削 hard turning, Koepfer 滾齒加工製造技術, Reinecker, KARSTENS外圓研磨+內圓曲面磨削, Naxos-Union軸研磨, 凸輪軸, KOPP非圓研磨, SW中心加工機, EMAG 雷射焊接, 自動化設備. oelheld 超高性能研磨切削油/EDM 放電加工液等, 其它非相關資料純粹供同好分享.  
 


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