Electrochemical grinding (ECG)
- Prof. SAVAN FEFAR
• The process is similar to ECM except that the
cathode is a specially constructed grinding
wheel instead of a cathodic shaped tool.
• The insulating abrasive material (diamond or
aluminum oxide) of the grinding wheel is set
in a conductive bonding material.
• the wheel is a rotating cathodic tool with
abrasive particles on its periphery.
• Electrolyte flow, usually NaNO3, is provided
for ECD (Electro chemical dissolution).
Working Principle
• The wheel rotates at a surface speed of 20 to 35
m/s, while current ratings are from 50 to 300 A.
• When a gap voltage of 4 to 40 V is applied
between the cathodic grinding wheel and the
anodic workpiece, a current density of about 120
to 240 A/cm2 is created..
• The current density depends on the material
being machined,, the gap width, and the applied
voltage
ECG machining system components.
MRR
• Material is mainly removed by ECD, while the
MA of the abrasive grits accounts for an
additional 5 to 10 percent of the total material
removal.
• Removal rates by ECG are 4 times faster than
by conventional grinding, and ECG always
produces burr-free
free parts that are unstressed.
unstressed
• The volumetric removal rate (VRR) is typically
1600 mm3/min.
The volumetric removal rate
(mm3/min) in ECG can be calculated
using the following equation:
• In the machining zone there is an area of
simultaneous ECD and MA of the workpiece
surface, where the gap width is less than the
height of the grain part projecting over the
binder.
• Another area of pure electrochemical removal
where the abrasive grains do not touch the
workpiece surface exists at the entry and exit
sides of the wheel.
• Machining conditions at which the MA
disappears depend on the electrical
parameters, electrochemical machinability
of the material in a given electrolyte, and
grinding wheel features especially grain
size and height.
• Generally slow feed rates produce larger
overcut, poor surface finish, and wider
tolerances, while excessive wheel wear
occurs as a result of a feed rate that is too
fast.
Accuracy and surface quality
• Traditional grinding removes metal by
abrasion, leaving tolerances of about ±0.003
mm and creating heat and stresses that make
grinding thin stock very difficult. In ECG
however a production tolerance of ±0.025 mm
is easily obtainable
• The ability to hold closer tolerances depends
upon the current, electrolyte flow, feed rate,
and metallurgy of the workpiece itself.
• ECG can grind thin material of 1.02 mm, which
normally warp by the heat and pressure of the
conventional grinding thus making closer
tolerances difficult to achieve.
• The main drawback of ECG is the loss of
accuracy when the inside corners are ground.
Because of the electric field effect, radii better
than 0.25 to 0.375 mm can seldom be
achieved
Applications
• Machining parts made from difficult-to-cut
difficult materials,
such as sintered
carbides, creep-resisting (Inconel
Inconel, Nimonic) alloys,
titanium alloys, and metallic composites.
• Applications similar to milling, grinding, cutting off,
sawing, and tool and cutter sharpening.
• Production of tungsten carbide cutting tools, fragile
parts, and thin walled
tubes.
• Producing specimens for metal fatigue and tensile tests.
• Machining of carbides and a variety of high-strength
high
alloys.
Advantages
• Absence of work hardening
• Elimination of grinding burrs
• Absence of distortion of thin fragile or
thermosensitive parts
• Good surface quality
• Production of narrow tolerances
• Longer grinding wheel life
Disadvantages
• Higher capital cost than conventional
machines
• Process limited to electrically conductive
materials
• Corrosive nature of electrolyte
• Requires disposal and filtering of
electrolyte
