NTM PPT for bachelor's for mechanical engineering

GOVT ENGINEERING COLLEGE
BEDARAPURA
NON-TRADITIONAL MACHINING [BME405A]
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGIEERING
FROM,
SURESHA G
2nd year.
4GE23ME428
MECHANICAL BRANCH

ELECTRO CHEMICAL GRINDING MECHINING

INTRODUCTION TO ELECTRO CHEMICAL
GRINDING MACHINING
Electrochemical grinding (ECG) is a process that removes material from a metallic
workpiece by electrolytic dissolution and mechanical abrasion.
The process is typically used for materials that are difficult to machine with
conventional methods, such as super alloys, titanium, and stainless steel etc.

PARTS OR CONSTRUCTION OF
ELECTROCHEMICAL GRINDING
 DC power supply.
 Work Table and fixture.
 Electrolyte tank.
 Pump.
 Filter.
 Pressure Gauge and
flow meter.
 Nozzle.
 Sleeve.
 Grinding wheel and
 Collecting tank.

PRINCIPLES OF ELECTROCHEMICAL
GRINDING
 Electrochemical Reaction: The process involves an electrochemical reaction
where an electrolyte (usually a conductive fluid) is used to create a path for the
electric current.
 Grinding Wheel: A grinding wheel made of non-conductive abrasive particles is
used, which is connected to the positive terminal of a DC power supply.
 Workpiece: The workpiece is connected to the negative terminal, completing the
circuit.
 Material Removal: Material is removed through a combination of electrochemical
dissolution and mechanical abrasion. The electrochemical reaction occurs at the
surface of the workpiece, where the material is dissolved, and the grinding wheel
removes the remaining material.

ADVANTAGES
 Can grind thin material of 1.02mm, which normally warp by the heat and pressure of
the conventional grinding.
 No work hardening.
 Stress free.
 Better finish.
 No cracking.
 Faster for tough materials.
 More precise tolerances up to 0.025mm.

LIMITATIONS
 Material Selection.
 Electrolyte Considerations.
 Setup and Maintenance.
 Surface Finish.
 Initial setup cost.
 Limited Material Removal Rate.
 Complexity for Large Parts.

APPLICITIONS
 Aerospace (for turbine blades and components).
 Medical devices (for precision components).
 Automotive (for fuel injection nozzles, gears, etc.).
 Electronics (for micro-machining).

CONCLUSION
Electrochemical grinding stands out as a sophisticated machining technique that
combines the benefits of electrochemical processing with the material removal
capabilities of conventional grinding. Its ability to achieve precise tolerances, high-
quality surface finishes, and efficient material removal makes it a valuable option
for industries demanding superior machining capabilities and enhanced component
performance.

ELECTRO CHEMICAL HONING MECHINING

INTRODUCTION TO ELECTO CHEMICAL
HONING MACHINING
ECH is a process in which the metal removal capabilities of ECM are combined with the
accuracy capabilities of honing. The process consists of a rotating and reciprocating tool
inside a cylindrical component.
Material is removed through anodic dissolution and mechanical abrasion – 8% or more
of the material removal occurs through electrolytic action.
As with conventional ECM, the workpiece is the anode and a stainless steel tool is the
cathode.

PARTS OR CONSTRUCTION OF
ELECTROCHEMICAL HONING MACHINING
 DC POWER SUPPLY.
 ELECTROLYTE
 FILTER
 HEAT EXCHANGER
 HONING STONES
 FIXTURE
 PUMP

WORKING OF ECH
At the beginning of the ECH cycle, the stones protrude only 0.075-0.127mm from the
stainless steel body, establishing the gap through which the electrolyte flows.
The electrolyte enters the tool body via a sliding inlet sleeve from which it exits into the tool-
workpiece gap through small holes in the tool body.
After passing through the gap, the electrolyte flows from the workpiece through the gap at
the top and bottom of the bore.
The mechanical action of the tool is the same as with conventional honing; the tool is rotated
and reciprocated so that the stones abrade the entire length of the bore.
Electrolytes used in ECH are essentially the same as those used in ECM, although the control
of pH, composition and sludge is less critical because the abrasive action of the stones tends
to correct any resulting surface irregularities.
As in ECM, the electrolytes are recirculated and reused after passing through appropriate
filtration, and the most commonly used electrolytes are sodium chloride and sodium nitrate

ECH TOOL CONSTRUCTION
 Tool consists of a hollow stainless steel body that has expandable, nonconductive
honing stones protruding from at least three locations around the circumference.
 The honing stones are identical with those used in conventional honing operations,
except that they must resist the corrosiveness of the electrolyte .
 The honing stones are mounted on the tool body with a spring-loaded mechanism so
that each of the stones exerts equal pressure against the workpiece.
 The length of the stones is selected to be approximately one-half the length of the
bore being processed.

NTM PPT for bachelor's for mechanical engineering

PROCESS PARAMETERS OF ECH
 Machines are available that deliver up to 6000 amp.
 Current density at the workpiece can range from 12 to 47amp/cm2.
 Working voltages are 6-30VDC.
 The electrolyte is delivered to the work area at pressures of 0.5-1MPa.
 ECH can remove materials at rates up to 100% faster than conventional honing, the
gain being more pronounced as the material hardness increases.
 Machine capacities are currently able to accommodate bore lengths up to 600mm and
bore diameters from 9.5 to 150mm.

ADVANTAGES OF ECH
 Increased MRR particularly on hard materials.
 Since most of the material is removed electrochemically, honing stone life is greatly
extended.
 Less pressure required between stones and work.
 Reduced noise and distortion when honing thin walled tubes.
 Cooler action leading to increased accuracy with less material damage.
 As with all ECM-based processes, ECH imparts no residual stresses in the workpiece.
 Capable of achieving surface finishes of 0.05µ and dimensional accuracies of
±0.012mm.
 By turning of the power to the tool before the end of the honing cycle, the stones can
be used in the conventional manner to achieve tolerances of ±0.002mm and to impart
a compressive residual stress in the work surface.

LIMITATIONS OF ECH
 High capital cost.
 Corrosive environment.
 High preventive maintenance cost.
 Non-conductive materials cannot be machined.
 Requires disposal and filtering of electrolytes.

APPLICATIONS OF ECH
 Surface Finishing and Smoothing.
 Internal Combustion Engines.
 Gear Manufacturing.
 Tool and Die Making.
 Hydraulic and Pneumatic Components.
 Medical Device Manufacturing.

CONCLUSION
Electrochemical honing is a specialized technology that combines electrochemical action
with mechanical honing to deliver superior surface finishes, precise dimensional accuracy,
and enhanced material properties. Its ability to handle complex geometries and improve
surface integrity makes it a valuable tool in modern manufacturing processes where
quality and performance are paramount.

NTM PPT for bachelor's for mechanical engineering

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