An Introduction to Electrochemical Discharge Machining (ECDM) Process and Its Research Potentials | Chapter 1 | Theory and Applications of Engineering Research Vol. 5

To machine "difficult-to-cut" materials including ceramics, glass, and silicon wafers, a hybrid and widely recognized process known as electrochemical discharge machining (ECDM) is used. It employs the working principle of electrochemical machining (ECM) and electric-discharge machining (EDM) processes to remove the material by combining chemical etching with thermal melting. The materials machined using ECDM exhibits enormous implementations in the field of MEMS and lab-on-chip. Different facets of the ECDM process have been researched in an effort to escalate its effectiveness ever since it was originally shown. The present chapter discusses the critical research potentials of the ECDM process that was documented in the past decades. Additionally, it covers the impact of several input process factors, including electrical, electrolyte, and tool electrode, on ECDM performance. A summarized report on ECDM hybridization, and variants are also given in a lucid manner. It also identifies future directions that might enhance the ECDM process's overall machining performance. It is concluded that with the help of gas film dynamics controlled by variables such as electrolyte characteristics and tool motions, ECDM can machine non-conductive materials with precision. Pulsed voltage, suggested electrolytes (NaOH, KOH), and regulated tool properties (material, shape, and rotation) are important factors. Spherical tool electrodes help minimize overcut and taper comparative to other tools while machining depth and geometrical accuracies can be further improved by implementing hybridization such as magnetic assistance & ultrasonic assistance.

Author(s) Details:

Sahil Grover,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

Viveksheel Rajput,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

Vikas Yadav,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

Sanjay Kumar Mangal,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

Sarbjit Singh,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

Sanjeev Kumar,
Mechanical Engineering Department, Punjab Engineering College, Chandigarh, India.

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Determining the Importance of Polarity Change in the Electrical Discharge Machining | Chapter 6 | New Visions in Science and Technology Vol. 3

The polarity change in spark erosion is still a concern, and it is frequently done in an arbitrary or unjustified manner. The removal electrode must be given the polarity indication first. This is often the cathodic workpiece electrode in EDM. The goal of this chapter is to describe the removal circumstances on the anode and cathode, as well as to explain how both electrodes' removal behaviour changes over time. The reversal point of the pulse duration may be established as a result of this, which is significant for the electrode material combination, the process energy source (PES), and the load circumstances. In order to validate the phenomenological models, experimental results with copper, aluminium, and iron are evaluated in combination with the same and various electrode materials. In the second stage, literature references are reviewed with the goal of determining whether or not there has been a polarity shift. The direct polarities are chosen largely to optimise removal while minimising wear. Second, reversal polarities are employed in finishing to achieve reduced surface roughness. A high level of wear must always be accepted in these applications, which account for the vast majority of the literature. The polarity of the PES and/or the load conditions of the PES is almost never mentioned in the literature, which leaves out a crucial aspect in the explanation of the results. The utilisation of electrical discharge in conjunction with other machining methods, such as electrochemical machining, necessitates a polarity change as well (ECM). An further impacting component is the primary removal process.

Author (S) Details

H. P. Schulze
Leukhardt Schaltanlagen Systemtechnik Magdeburg, Germany.

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