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Preface ix
1. Introduction 1
1. Introduction 1
2. The ECM Process 2
3. Characteristics of ECM Operation 4
4. Electrode Reactions 5
5. Electrochemical Micro Machining 8
6. Theory of Electrochemical Machining 10
7. Process Parameters 12
8. Epilogue 17
References 18
2. Machining Process 22
1. Introduction 22
2. Machining Operations 23
3. Review and analysis of the ECM and μECM machines available on the market 24
4. Design requirements and constraints for μECM systems 26
5. Process monitoring and control 27
6. Pulse power supply unit (PSU) considerations 39
7. Electrode and workpiece preparation 42
8. Epilogue 44
References 44
3. Measurement 48
1. Introduction 48
2. Measuring dimensions 48
3. Machine set-up 63
4. Surface roughness 68
5. Material grain structure and composition 78
6. Epilogue 84
References 84
vi Electrochemical Machining of Metals
4. Handling 88
1. Introduction 88
2. Electrodes and workpiece 89
3. Electrolytes 90
4. Epilogue 94
References 95
5. Modeling and Simulation 99
1. Introduction 99
2. Model for Material Removal Rate 100
3. Calculation of Electrochemical Constant 102
4. Calculation of Electrolyte Resistivity 103
5. Model for Deburring 105
6. Bin Wei’s PECM gap model with constant feed rate 107
7. Simulation 107
8. Epilogue 127
References 128
6. System Design 132
1. Introduction 132
2. Setup 134
3. Descriptiom of Components 139
4. Conair Electrolyte Pump 144
5. Design of Tool Holder 146
6. Design of Electrolyte Bath 149
7. Tool Setup 151
8. Workpiece Setup 152
9. Tool Positioning 153
10. Closed Loop vs Open Loop Operations. 154
11. Epilogue 163
References 164
7. Materials Investigated 167
1. Introduction 167
2. Choice of the Materials and their Physical Characteristics 167
3. Choice of the Electrolytes 173
4. Epilogue 190
References 190
8. Experiments 193
1. Introduction 193
2. Process Parameters 193
Contents vii
3. Drilling of Copper 193
4. Delamination 196
5. Drilling of Stainless Steel 197
6. Deburring of Copper 208
7. Epilogue 213
References 213
9. Experimental Equipment and Procedure 216
1. Introduction 216
2. ECM Equipment 217
3. Data Recording System 219
4. Typical Performance of a Run 221
5. Design of the Toolpieces 222
6. Epilogue 226
References 226
10. Results 230
1. Introduction 230
2. Titanium Carbide 231
3. Zirconium Carbide 239
4. Titanium Diboride 241
5. Zirconium Diboride 242
6. Epilogue 244
References 244
Index 249
Electrochemical machining, as a technological method, originated from the process of electrolytic polishing. Its use is limited to electrically conductive materials. ECM is sometimes referred to as "reverse electroplating," because it removes material rather than adds it. An electrolytic material removal process with a negatively charged electrode, a conductive fluid, and a conductive workpiece is similar in concept to electrical discharge machining in that a high current is passed between an electrode and the part through an electrolytic material removal process with a negatively charged electrode, a conductive fluid, and a conductive workpiece. ECM can cut small or odd-shaped angles, intricate contours or cavities in hard and exotic metals, such as titanium aluminides, inconel, and high nickel, cobalt, and rhenium alloys. The ECM technique is most commonly employed to manufacture complex forms with good surface quality in difficult-to-machine materials, such as turbine blades.
This book outlines the processes and applications of electrochemical machining in detail. It gives deep insights into the different concepts and methods used in this field. It explores various topics like machining process, measurement, handling, modelling and simulation. It also deals with system design, experimental equipment and materials. The various sub-fields of electrochemical machining along with technological progress that have future implications are glanced in this book. It is a complete source of knowledge on the present status of this field. This book, with its detailed analyses and data., will prove immensely beneficial to students involved at various levels.
Deedra Jenson is an Assistant Professor, Researcher, and Writer based at Houston. She is a Ph.D. holder in Electrochemistry from University of Science and Technology, Ontario. Her primary areas of scholarly and research interests lie in the fields of electrolysis, oxidation and redox reactions. Jenson has numerous papers, articles and book chapters to her credit. Her works have been published in various books as reference materials for students.