draw schematic sketch of electro chemical machining and explain

briefly the elements of ECM process.

Electrochemical machining (ECM) is a non-traditional machining process that uses an electric current
to remove metal from a workpiece. The workpiece is made the anode of an electrochemical cell, and
the tool is made the cathode. The electrolyte is a conductive fluid that flows between the workpiece
and the tool. When the current is applied, the metal ions in the workpiece are attracted to the cathode
and are removed from the workpiece. The tool is not consumed in the process, and the surface finish
of the workpiece is very smooth.

The main elements of the ECM process are :-

• Workpiece :- The workpiece is the material that is being machined. It is made the anode of the
electrochemical cell.
• Tool :- The tool is the electrode that is used to remove material from the workpiece. It is made
the cathode of the electrochemical cell.
• Electrolyte :- The electrolyte is a conductive fluid that flows between the workpiece and the
tool. It helps to carry away the metal ions that are removed from the workpiece.
• Power supply :- The power supply provides the electric current that is used to drive the ECM
process.
• Control system :- The control system controls the flow of current, the flow of electrolyte, and
the movement of the tool.
The ECM process works by passing an electric current between the workpiece and the tool. The
workpiece is made the anode of the electrochemical cell, and the tool is made the cathode. The
electrolyte is a conductive fluid that flows between the workpiece and the tool. When the current is
applied, the metal ions in the workpiece are attracted to the cathode and are removed from the
workpiece. The tool is not consumed in the process, and the surface finish of the workpiece is very
smooth.

The ECM process works as follows :-

1. The workpiece and tool are placed in a tank filled with electrolyte.
2. An electric current is applied between the workpiece and the tool.
3. The metal ions in the workpiece are attracted to the cathode (the tool) and are removed from
the workpiece.
4. The electrolyte carries away the metal ions.
5. The tool is slowly moved towards the workpiece to maintain a constant gap between them.

ECM is a very versatile process that can be used to machine a wide variety of materials, including steel,
titanium, and aluminum. It is particularly well-suited for machining hard materials and materials that
are difficult to machine using conventional methods. ECM is also used to machine complex shapes and
intricate details.

Some of the advantages of ECM include :-

• High accuracy and precision

• Smooth surface finish
• Ability to machine complex shapes
• Ability to machine hard materials
• Low tool wear

Some of the disadvantages of ECM include :-

• High cost
• Complex equipment
• Environmental concerns

ECM is a valuable tool for a variety of manufacturing applications. It is used in the aerospace,
automotive, medical, and electronics industries. ECM is a rapidly growing technology, and its use is
expected to continue to grow in the future.

Here are some examples of applications of ECM:

 • Machining turbine blades
• Manufacturing medical implants
• Making precision parts for the automotive industry
• Deburring machined parts

ECM is a powerful and versatile process that can be used to machine a wide variety of materials and
parts. It is a valuable tool for a variety of manufacturing applications.

Explain with neat sketch Electron beam machining. Also write its
advantages, disadvantages and application.

Electron beam machining (EBM) is a non-traditional machining process that uses a high-energy
electron beam to remove material from a workpiece.

Working :-

The electron beam is generated by an electron gun and focused onto the workpiece by a series of
magnetic lenses. When the electron beam strikes the workpiece, the kinetic energy of the electron
changes into heat energy. it causes the material to vaporize. The vaporized material is then carried
away by a stream of inert gas. The whole process takes place in vacuum. Vacuum environment is used
to prevent the contamination and avoid collision of electrons with air molecules. If the electrons collide
with the air molecules, it will lost its Kinetic energy.
EBM is a versatile process that can be used to machine a wide variety of materials, including metals,
plastics, and composites. The process is particularly well-suited for machining hard materials, such as
titanium and tungsten carbide, and for machining complex shapes and features. EBM can also produce
a high-quality surface finish.

Some of the advantages of EBM include :-

• Ability to machine hard materials

• Ability to machine complex shapes and features
• High-quality surface finish
• No heat-affected zone
• No burrs

Some of the disadvantages of EBM include :-

• Expensive equipment
• Slow process
• Requires a vacuum chamber

Here are some of the applications of EBM :-

• Medical implants
• Aerospace components
• Electronics
• Optics
• Jewelry