Electrochemical Die-Sinking (ECM) in Practice

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1 Electrochemical Die-Sinking () in Practice Copyright by Maschinenfabrik Köppern GmbH & Co.KG. Distribution, forwarding or duplication of this document, whether in part or in full, is only allowed with prior permission. page 1

2 1 Introduction is a process by which metal material removal is carried out by way of electrolytic dissolution. The technical process was developed to the stage of practical maturity in the USA, Russia and England during the 1950s, whereby electrochemical die-sinking was at first applied exclusively to the manufacture of complicated geometrical forms for aero-engines. After having been in use for 65 years in Germany, the process is now well-established in many industrial sectors. 1.1 Electrolytic cell 1.1 Electrolytic cell The principle of the process of electrochemical material removal is depicted in illustration 1.1 showing an electrolytic cell with an external power supply. This set-up comprises a power source, the power supply with the lead and contact resistances as well as the processing point between the cathode and the anode. The electrode/cathode is guided into the workpiece (anode), allowing electrolyte to flow through a working gap between the electrode and the anode. In most cases, sodium nitrate (NaNO 3) or sodium chloride (NaCl) are used, whereby a mix (NaNO3 + NaCl) is of course also possible. The electrolyte pressure reads between 5 and 30 bar and the working voltage between 4 and 30 volts. The electrolyte temperature is dependent on the material being page 2

3 processed, but is generally 30 C. The current density reads between 0.5 and 5 A/mm². 1.2 Process characteristics of electrochemical (EC) die-sinking Electrochemical machinability is largely a question of the chemical properties of the material rather than their physical attributes such as hardness or toughness. Characteristics of the process of electrochemical material removal are: only electrically conductive materials are electrochemically machinable hardness, toughness and cutting properties of the workpiece have only a minor influence on their machinability complex geometrical forms can be created machining at flat angles is possible, especially for drill holes small, deep holes can be produced flash-free machining no tool ware arising from the electrochemical process no thermal influences on the structure around the workpiece edges high material removal yield high surface quality high form precision high repeatability no processing tension thin-walled workpieces are machinable preliminary and final processing in one operation parallel processing possible with multiple tools very high replication precision and surface quality attainable with electrical and mechanical pulsing (P). The parameters of the electrochemical die-sinking process are dependent on the materials and the processes used. The inherent flexibilities are reflected in the broad range of the following processing parameters: page 3

4 Electric current Voltage Specific removal volume Die-sinking speed Electrolyte pressure Electrolyte flow Electrolyte temperature ph-value Conductance Electrolyte used 1 to 20,000 A 1-48 V up to 2 mm³/a min (material-dependent) mm/min 0.5 to 20 bar 0.1 l to 2,000 l/min 10 to 50 C ph to 400 ms NaNO3, NaCl 1.3 Chemical Processes The process of electrochemical material removal takes place by way of an external power source bringing about a forced electrical charge exchange and a material exchange by means of the electrolyte between the anode-poled workpiece (+) and the cathode as the tool (-). The principle of the anodal electrochemical dissolution of metallic materials is shown in illustration 2.1. By way of an electrical charge exchange (oxidation), material is removed at the positive-poled workpiece (anode). The metal cations produced in the electrolyte either remain dissolved or turn into insoluble metal hydroxides this depends on the ph-value. At the cathode, elements are reduced due to the electrical charge exchange, in a similar way to the decomposition of water when hydrogen is created. 2.1 Theoretical chemical processes in the working gap page 4

5 2 An die-sinking plant set-up 3.1 processing set-up A typical die-sinking plant consists of the following components: control, generator, work area and electrolyte supply. A direct-current generator converts 5-25V of direct current at a maximum of 40 Ka by way of an input transformer and a fully controlled high-current rectifier as actuator for an input voltage of 3x400 volts. The positive potential is applied to the workpiece and the negative potential connected to the electrode. Using centrifuges, filter presses and drying equipment, the gap between electrode and workpiece is flushed with a conductive electrolyte, which is subsequently cleansed by separating the metal hydroxide ions from the electrolyte in the form of bonded granulate that can be almost 100% reused. Within the electrolyte circuit, the ph-value, temperature, conductivity, volume flow and pressure are continuously measured in order to keep the processing parameters constant. The CNC-control calculates the guiding movement of the spindle axes. page 5

6 3.1 Rundtisch Anlage The illustration shows a die-sinking plant in which the guiding movement is carried out horizontally. The working enclosure slides over the workpiece/tool during processing. This is essential as electrolyte leaks are always possible. The work surface shown here is freely programmable in terms of the spacing of torsionally symmetrical workpieces. The power supply / electrical contact is carried from the anode side through the middle of the work surface. The cathode side is connected via electric cable to the quill plate. The illustrated segmental form ring with an outside diameter of 1,011 mm is designed for roller presses used for the briquetting/compaction of various materials such as combustibles, coking coal, ores and minerals, sponge iron, metals, ceramic masses, potash salt or chemical products. The conventional manufacture of such forms is uneconomical in terms of their geometry and in some cases unfeasible due to extreme hardness. Quite apart from that, many forms carry inscriptions that get directly transferred to the workpiece. Today one can say that equipment has attained the standards of machine tools. When building an machine, one should take care that all machine parts that come into contact with the electrolyte are made of stainless steel or, if possible, plastic. This applies especially to the work surface and the interior, but also to auxiliary units. Following the purchase of equipment, all auxiliary units should be positioned separately from the actual machine. This has to do with noise levels created by pumps and centrifuges, as well as with safety aspects. page 6

7 With costs of around 1.5 mill. Euros for a 10,000 A machine, including all operational activities, it is important right from the start to assess whether one s capacity requirements warrant the investment. contract manufacturing offers an alternative that gives beginners a good opportunity to get to know this process. machining does of course have its limits, for example the very high cost of purchasing the equipment. Tooling costs for small production runs are also an important factor. Whether or not is economically viable for a specific requirement should always be assessed on a case-by-case basis. Tolerances in machining are mainly dependent on the tool design. As a rule, tolerances of +/- 0,1 mm can be achieved with a multi-purpose tool. Smaller tolerances, down to say +/- 0,05 mm, are achievable with individual tools, but this requires a significantly higher outlay for fixtures. In any case, all the selected parameters, such as conductivity of the electrolyte, working voltage, guided movement and temperature must be kept within narrow tolerances. machines with pulsing technology, also known as Ps, can create spatial forms at around +/-0,01 mm, taking into account the systemic limits already mentioned above - whereby the tool remains technically wear-free. However, in practice the tooling should be overhauled after processing several hundred or up to a thousand parts. Damage due to a short circuit at the electrodes, or mechanical effects / chemical dissolution in certain areas of the tool, make regular maintenance a necessity if serious tolerance fluctuations are to be avoided. As a rule of thumb, tolerances should be set in proportion to the number of electrodes required per working operation. Another factor in achieving good machine performance is the best possible tool configuration in terms of choice of material, electrical contact or the direction of flow of the electrolyte. page 7

8 2.1 Flow pattern of the electrolyte Regarding the flow direction of the electrolyte, we distinguish between three of the most common basic forms: 4.1 Different electrolyte flows 1. The electrolyte is fed into a pressure chamber and flows back through the electrode. 2. The electrolyte feeds in through the electrode and flows out through the working gap. This takes place either in free flow or by way of a pressure chamber in which a corresponding counter-pressure can be created. 3. The third example shows a set-up whereby the electrolyte is fed across the electrode. In contrast to the other two examples, due to the flow channel this does not produce the flow grooves that arise in examples 1 and 2. The material used in making the tools is generally stainless steel, copper, tungsten copper, plastic based on epoxy resin, brass or bronze. Recently, graphite has also been used for voluminous workpieces. 2.2 Role of the gap in die-sinking For the production of cylindrical profiles, the front- and side-gaps remain practically constant under consistent working conditions. This is achieved by insulating the tool electrodes and neighboring components in order to assure a defined material removal capability in the side-gap. Cylindrical profile Space form page 8

9 5.1 Geometrical view of the working gap For the production of spatial forms, insulation of the corresponding surfaces, as required for example for the briquette hollows mentioned above, is not necessary which is why material removal is greater in the side-gaps than in the front-gaps. 3 Advantages and disadvantages of machining Some particular advantages of the process are: no thermal effects on the working material high repeatable accuracy good surface structure flash-free machining no electrode wear processing of hardened parts more freedom of design. Disadvantages arise with regard to complex forms because machining is not suited to small production runs due to the extremely costly electrode optimization. equipment is also comparatively costly and though tolerances can be achieved right down to the hundredths, this is only possible at relatively high expense. page 9

10 4 Differences between processing and spark erosion (EDM) EDM no material removal at the electrode material removal at the electrode minor hardening of the workpiece surface applicable for mid- to large series no hardening of the workpiece surface applicable for small series (down to 1 piece) high material removal capability low removal capability tolerances +/ tolerances generally +/ Areas of application processing applications as described here are used today in the following sectors: Aerospace: Engine parts, housings, turbine blades, cooling holes Automotive: Gearing, piston weight reduction Medical technology: Tablet rollers, hip joint prostheses Energy technology: Filter elements, turbine rotors Food machines: Baking plates Oil hydraulics: Valve plates page 10

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