Chapter 5

Electrochemical Based Hybrid Machining

Dr. J. Ramkumar1 and Prabhu Dayal2

1Professor and 2Research Student

Department of Mechanical Engineering

Micromanufacturing Lab, I.I.T. Kanpur
Micromanufacturing Lab, I.I.T. Kanpur
 Organization of the presentation

1. Introduction-Electrochemical Based Hybrid Machining

2. Classification of Ecm-Based Hybrid Machining Process

3. Assisted ECM Based Hybrid Process

(Laser-assisted jet ECM, Ultrasonic-assisted ECM, Abrasive-assisted ECM )

4.Combined ECM Based Hybrid Process

(Laser-ECM, Electrochemical Discharge Machining(ECDM), Combined Electrochemical
Grinding, Mechano- Electrochemical Machining, Electrochemical honing )

5. Concluding Remarks

6. Summary of ECM-Based Hybrid Process

7. References

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 Introduction-Electrochemical based Hybrid Machining
ECM- based hybrid machining process will
Several hybrid machining process are resorting
combine other types of energies( mechanical,
to ECM as one of the candidate process
Abrasive, lase/ heat , ultrasonic) to enhance the
because of the following advantages of ECM;
material removal of ECM process. Based on the
1. Independent of workpiece hardness.
types of combined energies, ECM based hybrid
2. Complex shapes can be machined.
machining process can be classified as-
3. ECM has no tool wear and high surface
1. Assisted ECM
finish as dissolution occurs at atomic level.
2. Combined ECM
4. Material removal rates can be controlled
from electrical parameter( voltage , current ,
energy) and pulse characteristics ( pulse
frequency , on time , duration , duty cycle).
3
Fig: Ultrasonic – two axis vibration Assisted Polishing[1]
 ECM BASED HYBRID MACHINING PROCESS CLASSIFICATION

Assisted ECM based hybrid process Combined ECM based hybrid process

Laser-assisted jet ECM Laser-ECM

Electrochemical Discharge Machining(ECDM)

Ultrasonic-assisted ECM
Combined Electrochemical Grinding
Abrasive-assisted ECM
Mechano- Electrochemical Machining

Electrochemical honing

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 Assisted ECM Based Hybrid Process-(1) LAJECM

Laser assisted jet electrochemical machining

(LAJECM) is a hybrid process, that combines
a laser beam with an electrolyte jet thereby
giving a non-contact tool electrode that
removes metal by electrochemical dissolution. Fig : LAGECM Apparatus Layout (a) Machining Chamber
(b) Jetcell [1]
The laser beam effectively improves the
precision of LAJECM as it is able to direct the
dissolution to specifically targeted areas. This
prevents the machining from unwanted areas
due to stray current.

Fig : Energy Balance of LAJECM[1] 5

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 LAJECM PROCESS PRINCIPLES
LAJECM combines two different sources of energy simultaneously: energy of ions (ECM) and
energy of photons (a laser beam). The main aim of combining a laser with a jet of electrolyte
(giving a laser-jet) is to assist electrochemical dissolution from a specific workpiece surface area.
Electrochemical dissolution is the main material removal mechanism supported by the parallel
action of the low power (average power of 375 mW) laser beam.

Fig: Volumetric Removal Rate Vs. Voltage and Fig. : illustrates the principles of hybrid LAJECM [1]
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IEG for Stainless Steel Micromanufacturing Lab, I.I.T. Kanpur
Thermal energy enhances the kinetics of
electrochemical reactions providing faster
dissolution. It also aids in breaking down the oxide
layer found on some materials in certain
electrolytes that inhibit efficient dissolution. Fig. 2. (a) Jet-ECM without directed dissolution, and
(b) LAJECM with intensified dissolution in the
localised zone.[1]

The advantage of LAJECM is that the laser beam

can be easily aimed on the workpiece surface and
therefore, together with the flushing electrolyte
jet, dissolution can be accelerated in any desired
direction. This ‘localisation effect’ enhances Fig: Micrograph of a hole drilled with LAJECM [1]

accuracy by limiting stray machining action . 7

Micromanufacturing Lab, I.I.T. Kanpur
 Disadvantages of LAJECM Electrical Discharge
crater Located to one
1. Basically the laser beam must be maintained side of the cavity edge
coaxially with an electrolyte jet and in a single Cavity Edge

spot on the workpiece. This is obviously

difficult due to the hydrodynamic behaviour of
the jet as well as the gas evolution at the
cathode.
2. Gas evolution may also disturb a jet making
the electrolyte flow more turbulent and thus
causing the laser-jet spot to drift. Fig: Spark damage due to electrolyte boiling [1]

3. Electrolyte boiling and electrical discharges

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 Ultrasonic Assisted Electrochemical Machining (USAECM)

1.To improve technological factors in electrochemical

machining, introduction of electrode tool ultrasonic vibration
is justifiable. This method is called as ultrasonically assisted
electrochemical machining (USAECM).
2.The objective of ultrasonic assistance in ECM is multifold.
The ultrasonic vibration facilitate removal of reaction by-
product and heat from machining zone , favors diffusion ,
minimizes passivation , creates optimal hydrodynamic Fig : Schematic of ultrasonic-assisted
electrochemical machining [2]
conditions, improve aspect ratios, and influences electrolytic
reactions through sonochemical reaction.
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 Fig. Ultrasonic Assisted Electrochemical Machining[2]

The set mainly consist of a direct current (DC) pulsed power supply, motion control system,
electrolyte circulation system, ultrasonic head, which consist of a transducer coupled with
ultrasonic generator, and horn for transmitting ultrasonic energy to the tool. The use of
ultrasonic frequencies of 28 kHz, 40kHz, 20kHz, and 1.7 MHz depending on the process
configuration and method of actuation . 10
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Thus, the electrolyte flow and electrochemical reactions are benefited. The ultrasonic wave
traveling in Z direction can be represented as a longitudinal wave as in --

……………………………(1)

In the above equation, P is the pressure acting on the upper surface of the micro-cell, 𝐏𝟎 is the
pressure acting on the boundary surface between the electrolyte and air, ρ is the density of the
electrolyte, g is the acceleration due to gravity, ω is the frequency of the ultrasonic wave, c is the
wave speed, t is the time, A is the amplitude of the wave, and h is the distance between the fluid
surface and the end of the electrode. The higher the frequency of the ultrasonic vibrations, the
greater the pressure on the micro-cell. The maximum or minimum pressure with respect to the
frequency can be obtained by partial differentiation of Eq. (1):

…………….……………….(2)
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From equation (2), applying the condition of maxima – minima, it can be deduced that maximum
and minimum pressure occurs at points which satisfy the following equation (3).

……………………………………(3)

From equations (2) and (3), it can be inferred that the maximum pressure occurs a given point (z)
increases with the ultrasonic frequency.
1.Hence, ultrasonic vibrations are responsible for frequent and larger pressure increases in the
machining gap and this leads to enhanced electrolyte diffusion and elimination of bubble.
2.Besides the process parameters (current density, voltage, pulse parameters, and electrolyte
concentration) involved in ECM, the amplitude of ultrasonic vibration plays an important role.
3.Low amplitudes don’t give additional benefits. Too high amplitudes affect machining precision
especially while machining microdimensional features. 12
Micromanufacturing Lab, I.I.T. Kanpur
 ABRASIVE –ASSISTED JET – ELECTROCHEMICAL MACHINING
In abrasive –assisted jet ECM , abrasive are used
to facilitate material removal by jet ECM. One
such example is electrochemical slurry jet
machining. The abrasive (𝐀𝐥𝟐 𝐎𝟑 ) slurry in the
electrolyte( NACl) facilitates removal of a
passivating layer by impact action on the
workpiece . This process is particularly suitable
Fig; Schematic of electrochemical slurry jet micro-
for machining of WC ( tungsten carbide) which machining (ESJM)[3]
undergoes excessive corrosion and passivation
under jet-ECM. The working voltages ranges
from 60 V to 120 V.
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 ABRASIVE
FEEDER

MIXING
PUMP
CHAMBER
Valve

NOZ
Electrolyte flow -ZLE

WORKPIECE

FILTER
Fig : Schematic of electrochemical slurry jet micro-machining 14
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 COMBINED ECM BASED HYBRID PROCESS
1. Mechano-Electrochemical Milling (MECM)
1.This hybrid machining process combines the effect of both the conventional milling process
and the Electrochemical Machining process (ECM). The MECM is under development with an
objective to machine difficult-to-cut materials with improved productivity and better surface
quality .
2.The MECM process is especially useful in
machining of hard metal such Ti6Al4V which suffers
from surface passivation during the ECM process.
The mechanical process facilitates removal of
passivation by a cutting edge , thereby enhancing
the surface quality and process stability . The process
Fig: Schematic overview of a MECM setup[4]
needs dedicated tool design of a tools. 15
 2.Electrochemical Grinding (ECG)
1.In ECG , the material removal is achieved by
combined action of abrasive and electrochemical process
energy. The resulting surface has high surface integrity,
is burr free, and has negligible distortion.
2.The abrasive particles of the grinding wheel make a Fig : Schematic of electrochemical grinding

contact with the workpiece and the gap between the

wheel and workpiece makes passage for electrolyte
circulation. The gap voltages range from 2.5V to 14V. At
the start of machining process, the material removal is
achieved by the action of electrochemical process and
this is followed by the development of passivating layer
Fig: Burr Free Electrochemical Grinders
16
on the workpiece surface. Image source: Tridex Technology
 3.The MRR in ECG is a result of synergic interaction
of three subprocesses, i.e., electrochemical dissolution,
mechanical abrasion, and erosion process and can be
estimated using a simplified model as ……..

The MRRs due to individual process energy can be

Fig Schematic of electrochemical grinding for
drilling [5] estimated using following equations:
………………(4)
where, η, I, A, z, ρ, F, 𝑽𝒆 , 𝐊 𝐩 , w, 𝐅𝐚 , and IEG are current efficiency, machining current,
molecular weight of anode, valency of positive or negative ions, density of workpiece, Faraday’s
constant, applied voltage across electrodes, degree of polarization, specific conductance of
electrolyte, active surface area of anode, and size of interelectrode gap, respectively. 17
 Fig. Schematic of flow of electrolyte gas mixture in
Fig : Schematic of electrochemical grinding cylindrical micro-ECG [6]

where dg, dl/dt, 𝐝𝐦𝐞𝐚𝐧 𝐝𝐦𝐚𝐱 , 𝒅𝐜𝐨𝐧𝐭𝐚 , and ρ are average size of abrasive grain, feed rate, mean
grain diameter, maximum grain diameter, the diameter of grain just contacting the workpiece
surface, and density of electrolyte, respectively. 𝐍𝐭𝐨𝐭𝐚𝐥 is total number of grains coming into the
18
machining zone per unit time. a is machining gap. Image source : Tridex Technology
 …………..(5)
where, 𝐀 𝐬 is shear area (width of grinding wheel x projected contact length). 𝐀 𝐈𝐄𝐆 is area of
interelectrode gap (product of IEG and width of grinding wheel). ρ is density of electrolyte.
H: is head. Fs :is shear force, C : is correction factor.
Applications Of ECG

Fig: Point Grinding through ECG

Fig: Miscellaneous product made through ECG

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Image source: Tridex Technology Micromanufacturing Lab, I.I.T. Kanpur
 3. Orbital Electrochemical Abrading

1.In orbital ECA, a three-dimensional abrasive

cathode is used which has a multiaxis orbital
motion and is oscillated mechanically .
2.The tool and workpiece also undergo
reciprocating motion which facilitates
Fig. Sketch of orbital electrochemical abrading [7] electrolyte flow in the gap.
3.The orbital motion of the abrasive cathode
4.The areas where abrasive action has not acted
facilitates the removal of a passive layer of
retain the passive layer. This helps in
formed on the workpiece surface . The orbital
preventing stray machining.
motion of the tool enables uniform distribution
5.Therefore, orbital ECA offers controlled and
of electrolyte and improves ECM performance.
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localized removal of workpiece material.
 4. ELECTROCHEMICAL HONING (ECH)

Fig :Proposed process principle of Ultrasonic ECH Fig : Schematic view of the ECH setup used for finishing of
of bevel gear.[8] workpiece . [8]

1. Electrochemical honing (ECH) is a hybrid process of ECM and mechanical honing and is used
in finishing of complex shaped products, such as helical and bevel gears, external and internal
cylindrical surfaces.
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 2. The setup consists of two cathodic bevel
gears (I and II) meshing with the
workpiece bevel gear which acts as an
anode. The cathode gear-I consists of an
insulating layer of Metalon sandwiched
between two conducting layers of copper
Fig. Sketch showing working principle of
electrochemical honing for finishing of bevel gears[9] with a 1-mm undercut.

3.The electrolyte is supplied in the interelectrode gap and the workpiece gear undergoes finishing
by electrochemical dissolution. This is followed by development of a passivating oxide layer on
the gear teeth and this prevents further electrochemical dissolution.

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4. Subsequently, the mechanical honing action comes into the picture which removes the
passivating layer. The mechanical honing action is accomplished by using a honing gear which is
mounted in a tight mesh and perpendicular to the workpiece as well as cathode gears.
5.The material removal in ECH is the sum of volumetric material removal due to electrochemical
action and mechanical honing as in Equation given below.

MRRECH = VECM + Vhoning ……………………(6)

where, VECM can be computed from Faraday’s Law of electrochemical dissolution, and Vhoning can
be calculated from Archard law of wear. Substituting the expressions for MRR for
electrochemical dissolution and mechanical honing, Equation (6) can be rewritten as Equation (7).

ηEJAs KFnS
MRRECH (mm3/s) = + ………………………….(7)
Fρ H
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where, η denotes current efficiency, E stands for electrochemical equivalent of workpiece material
(g), F denotes Faraday’s constant (96500 C), ρ is density of workpiece gear material (g/cu.mm),
As is surface area of gear tooth (depends on type of gear and its geometry), J is current density in
this area (A/ mm2); K denotes wear coefficient of the workpiece material, Fn is the total normal
load acting along the line of action, S is total sliding distance (mm), and H stands for Brinell
hardness number of the workpiece material (N/sqa.mm).
Application of ECH

Fig :Photograph of a typical tool for ECH of internal

Fig : Schematic of a typical tool for ECH of internal cylinders cylinders
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Image source: tridex technology
 5. ELECTROCHEMICAL DISCHARGE MACHINING (ECDM)
1.In electrochemical discharge machining (ECDM) process, the capabilities of ECM and EDM
processes are combined with each other to expand the processing window from conductive to
nonconducting materials as well as to fabricate deep microholes, microchannels, etc. .
2.The setup consists of two electrodes, i.e., tool as cathode and an auxiliary electrode (anode),
and the workpiece is kept below the tool electrode. A pulsed DC current is supplied between
cathode (tool) and anode.

Fig.Sketch showing setup and process mechanism for

electrochemical discharge machining [10] Fig. Schematic of ECDM setup [12] 25
3.An optimum gap is maintained and electrolyte is passed through the gap. The ECDM process
involves two major phenomenon: electrolysis leading to generation of gas bubbles and arc
discharge due to breakdown of gas film.

Fig. Current and voltage waveforms for Fig:(a) Micro-grooves, (b) enlarged figure of micro-grooves, (c) micro-pillar,
electrochemical discharge machining[11] (d) micro-wall, and (e and f) micro-pyramid machined on glass by ECDM
(KOH 30 wt%, 23 V pulse voltage, 1 ms/1 ms pulse on/off-time ratio, Ø 30–
26
33 μm tool, 3 μm/s feedrate and 300 rpm rotational speed)[11]
4.The wettability of tool electrode affects
micromachining resolution . It has been
observed that applied voltage is the influential
parameter which influences MRR, HAZ
thickness as compared to electrolyte
Fig : Micro ECDM experimental setup [12]
concentration, tool immersion depth, and
interelectrode gap in micro-ECDM drilling.
ECDM micromachining has been demonstrated
on a variety of nonconducting materials, such
as glass , pyrex wafer, alumina , quartz, and in
trueing and dressing of metal-bonded diamond Fig : Tool rotation effects (a) no rotation and (b) with tool
rotation at 1500 rpm [12]
grinding 27
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 Concluding Remarks

This chapter presented a discussion the fundamental aspects of electrochemical-based hybrid

machining processes. The main benefits of hybridizing ECM with other processes are restated
below:
1. To combine high MRR and high surface finish during deep hole drilling (ECDM).
2. To achieve better process localization and minimize lateral machining (LAJECM).
3. To achieve better flushing/circulation of electrolyte in the machining gap (UAECM).
4. To break the passive layer formed on the workpiece in ECM process (UAECM, ECG).

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Micromanufacturing Lab, I.I.T. Kanpur
 Concluding Remarks

For successful hybridization of micro-ECM with other process energies and to realize it in
machining, several technological requirements have to be met and are listed below :
1. Development of Universal machine tool capable of combining ECM with two or more
processes.
2. Synchronization of ECM process energy with other process energies such as laser,
micromilling, EDM by parametric optimization for better process and shape control.
3. Better understanding of material removal mechanisms under the simultaneous action of two or
more process energies.

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 Summary of ECM-Based Hybrid Process
ECMM-based Process Main process Advantages
hybrid process Energies Parameters
involved

Laser-assisted Laser, laser pulse energy, repetition rate, Improved reaction

electrochemical electrochemical ECM parameters (voltage, current kinetics, localized
machining density, electrolyte type, material removal
concentration, pulse parameters)
Laser average power,
Ultrasonic Ultrasonic Ultrasonic frequency and Improved
assisted vibration amplitude, tool design, ECM electrolytic
electrochemical (mechanical) parameters (voltage, current diffusion, improved
machining and density, electrolyte type, mass and charge
electrochemical concentration, pulse parameters) transport, reduced
passivation
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 Summary of ECM-Based Hybrid Process
ECMM-based Process Energies Main process Advantages
hybrid process involved Parameters

Abrasive Abrasive impact Concentration of slurry, abrasive Removal of

assisted (mechanical) and particle size, speed, stand-off passivating layer,
electrochemical electrochemical distance, ECM parameters (voltage, stabilization of
machining current density, electrolyte type, electrochemical
concentration, pulse parameters) dissolution

Laser Laser, Laser average power, laser High MRR with

electrochemical electrochemical wavelength, laser pulse energy, good surface
machining repetition rate, ECM parameters finish, reduced
(voltage, current density, electrolyte thermal defects
type, concentration, pulse of laser, i.e.,
parameters) spatter, recast
layer, HAZ 31
ECMM-based Process Main process parameters Advantages
hybrid process energies
involved

ECDM Electrochemical Gap voltage, gas film thickness, Machining of

and arc pulse duration, electrolyte type, nonconductive
discharge concentration, conductivity and materials, high MRR,
flow rate, tool material and good surface
finish

Combined Electrochemical, Grinding wheel type (grit size, Removal of

electrochemical abrasive cutting bond type), wheel RPM, ECM passivating layer,
grinding (mechanical) parameters (voltage, current stabilization of
density, electrolyte type, electrochemical
concentration, pulse dissolution, improved
parameters) MRR
32
ECMM-based Process Main process parameters Advantages
hybrid process energies
involved

Mechano- Electrochemic- Cutting edge radius, RPM, tool Removal of passivating

Electrochemic- al and feed rate, ECM parameters layer, high MRR
al machining mechanical (voltage, current density,
(cutting edge) electrolyte type, concentration,
pulse parameters)

Electrochemic- Electrochemic- Tool RPM and reciprocation, Finishing of complex

al honing al, mechanical abrasive type and grit size, shaped parts such as
honing processing time, ECM helical or bevel gears,
parameters (voltage, IEG, external cylindrical
current density, electrolyte type, surfaces.
concentration, pulse
parameters).
33
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Micromanufacturing Lab, I.I.T. Kanpur
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[8] Harpreet Singh and Pramod K Jain, Study on ultrasonic-assisted electrochemical honing of
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[9] J.H. Shaikh, N.K. Jain, Modeling of material removal rate and surface roughness in finishing of
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