Electrochemical machining – state of the art and direction of development

Abstract

Electrochemical machining process (ECM) can be applied for efficient shaping advanced materials conducting electrical current, which are difficult or impossible for machining using conventional methods. In electrochemical machining, the workpiece is an anode and material is removed as a result of electrochemical reactions “atom by atom” without mechanical forces. This mechanism of material removal make it possible to obtain high quality of machined surface layer with uniform properties. The very important advantage of ECM process is also the fact that there is not a tool wear (working electrode – cathode), because the equivalent reaction to anodic dissolution is hydrogen generation on cathode surface and hydrogen can be easily removed from, the inter-electrode gap by electrolyte flow. Because of this advantages, the ECM process is widely applied in space, aircraft, car and electromechanical industry and research stimulating ECM development are carried out.

Selected Aspects of Electrochemical Micromachining Technology Development

“…Recent developments in ECM, especially in the area of PECM, allows to apply this method to accurate shaping of 3D structures with machining area from several to tens square millimetres with accuracy similar to milling or EDM sinking [ 17 , 18 , 19 , 20 , 21 , 22 ]. Due to development and improvements of machine-tools, power suppliers, electrolyte stations, and control systems, the technological borders of PECM were shifted toward more accurate and precise machining.…”