Lecture note on ELECTRO CHEMICAL DISCHARGE MACHINING (ECDM)
1. INTRODUCTION
Electrochemical discharge machining (ECDM) is an advanced hybrid machining process
comprising the techniques of electrochemical machining (ECM) and electro discharge machining
(EDM). The process is also referred as electrochemical spark machining (ECSM) process. The
process is important since it can machine a variety of electrically non-conducting materials
including ceramics, composites, alumina, glass, etc. The process has possible potential usage in
the following areas:
⮚ Micro-fabrication of miniature machine tools for micromachining
● Micro-fabrication of array of holes in SU-8 material (high aspect ratio, polymer,
dielectric photoresist material) to fabricate micro-filters needed in micro-EDM process
● Micro-seam welding of copper plates and foils
● Fabrication of miniature components
● Heat treatment.
Hence, electrochemical processes are being reconsidered for the micro-fabrication purposes.
2. NEED OF ECDM PROCESS
⮚ Engineers reached the performance limit of metals
⮚ Non-conducting materials are very popular in modern manufacturing industries
⮚ Difficult to generate 3D features or to produce components or products with glass,
ceramics, etc by the common conventional machining processes
⮚ Most of the non-conventional machining process such as ECM, EDM, etc, fails to
produce features on glass, etc due to their inherent problems
Diamond Wheel Grinding- The diamond wheel is easily worn during machining and the worn
wheel is difficult to be dressed, so that the method shows incurs machining costs.
Abrasive jet machining- It produces a taper in deep cuts
Abrasive Water Jet Machining (AWJM) - Low metal removal rate, embedding of abrasive in
work piece, tapering of drilled holes and possibility of stray abrasive action
Laser Beam Machining (LBM)- Large heat effected zone, High capital and operating cost and
low machining efficiency
Ultra Sonic Machining (USM)- The material removal rate is extremely low, tool wears laterally
and longitudinally
3. PROCESS MECHANISM IN ECDM
A general electrochemical cell consists of two electrodes dipped in electrolyte. If the two
electrodes are of grossly different sizes; at least area of one electrode is hundred times
greater than that another electrode (auxiliary/ counter electrode) then beyond a certain
value of applied voltage, electric sparks appear across the electrode–electrolyte interface
on the smaller electrode and the cell current drops. This is known as electrochemical
discharge (ECD) phenomenon. Electrochemical Discharge Machining (ECDM) process,
a hybrid technology, is a combination of two machining processes i.e. Electro-chemical
Machining (ECM) and Electro-Discharge machining (EDM). Application of external
potential between the electrodes causes the flow of electric current through the cell,
resulting in electrochemical reactions such as anodic dissolution, plating of cathode,
electrolysis etc. Electrochemical reactions help in the formation of gas bubbles, which are
responsible for electro-spark discharge (ESD). As soon as an electrically non-conducting
workpiece is placed in the close vicinity of discharges, the material of the workpiece is
removed by melting, vapourisation due to the energy released by sparks.
4. THE CHEMICAL REACTIONS
The chemical reactions at cathode (tool):
2H+ + 2e- → H2 ↑ (in acidic electrolytic solution)
2H2O + 2e- → 2(OH)- + H2 ↑ (in alkaline solution)
Me + e- → Me
+
The chemical reactions at the auxiliary/ counter electrode (Anode):
2H2O → O2 ↑ + 4H+ + 4e- (in acidic electrolyte solution)
4(OH)- → 2H2O + O2 ↑ + 4e- (in alkaline electrolyte solution)
Me → Me+ + e-
5. MATERIAL REMOVAL MECHANISM
Each electrical discharge causes a focused stream of electrons with a very high velocity
and acceleration from the cathode (or tool) towards the workpiece and compressive shock
waves on the workpiece surfaces. The high pressure of the compressive shock waves
creates a blast, causing metallic vapours to form wear products in the shape of metallic
globules, leaving craters on the workpiece surface. The phenomenon is accomplished
within a few microseconds and the temperature of the spot hit by electrons may rise to a
very high value. As this high temperature is above the melting point of workpiece
material, it melts and finally evaporates the material. Ceramic materials removed due to
thermal spalling where the material removed is due to mechanical failure without
melting.
Fig. 1 Schematic representation of discharges in ECDM process
6. ECDM SET-UP AND ITS COMPONENTS
(a) Mechanical hardware system
(b) Electrolyte supply system
(c) Electrical power supply unit
Although, the above components are main three components of a typical ECDM se-up,
the actual components are as follows:
(i) Main machine chamber
(ii) Job holding unit
(iii) Tool holding unit
(iv) Inter-electrode gap control unit
(v) Auxiliary electrode unit and
(vi) Gravity controlled job feeding arrangement
Fig. 2 Schematic diagram of an ECDM set-up
Specification details of electrical power supply unit
Main input power supply : 3 phase 440V A.C.
Power supply : Pulsed D.C.
(i) Voltage range : 0 to 200V.
(ii) Range of current : 0 to 20 Amps.
7. PROCESS PARAMETERS AND THEIR INFLUENCES ON PERFORMANCE
(A) Effect on Material Removal Rate (MRR)
(i) Applied voltage
At low applied voltage, the MRR is very low. MRR increases with the increases in
Voltage but at very high voltage total rupture of the sample.
(ii) Electrolyte concentration
At higher electrolyte concentration (30%), more electrochemical reactions occur between
the tool and auxiliary/ counter electrode, which in turn produce more gas bubbles at the
sparking zone, with the generation of a greater number of sparks.
(iii) Voltage frequency and duty ratio:MRR decreases as the voltage pulse frequency
increases and the duty ratio decreases but machined surface becomes rougher.
(B) Effect on Accuracy/ Overcut (OC)
(i) Electrolyte concentration
At 25% NaOH solution, the overcut is much lower compared as to that for 20% and 30%
concentration due to the fact of concentrated and controlled spark generation from the
front face of the tool tip.
(ii) Tool shape
MRR increases considerably for taper side wall-curvature front tool tip compared to the
straight side wall-flat front and, the taper side wall-flat front tool tip.
OC minimum for taper side wall-curvature front tool tip and maximum for straight side
wall-flat front.
(C) Effect on Heat Affected Zone (HAZ)
Thickness of HAZ increases….
with an increase in applied voltage due to a high intensity of sparking.
decreases with increase in inter-electrode gap
(D) Effect on Tool Wear Rate (TWR)
Tool wear rate increases with the increase in voltage. Also tool wear rate increases with
an increase in specific conductance of tool material. However, tool wear rate decreases
with an increase in tool diameter.
8. ADVANTAGES AND DRAWBACKS OF ECDM PROCESS
8.1 Advantages of ECDM Process
Electrically non-conducting material (glass, ceramics, fibre composites, quartz) can be
machined
Low heat affected zone and low cost
8.2 Drawbacks of ECDM Process
Limited depth of machining,
High overcut due to side sparking and,
Poor surface finish
8. APPLICATIONS OF ECDM PROCESS
The electrochemical discharge machining (ECDM) process can be utilized effectively for
the machining of non-conductive materials such as glass, ceramics and advanced
composites considering the capability of machining a complex profile.
The ECDM process has the potential for macro- and micro-hole drilling operations on
ceramic components.
The ECDM technology has the possibilities and feasibilities to slice non-conductive
materials.
The ECDM technology can be used for engraving on electrically non-conducting
materials.