Electrochemical machining, and check out Electrochemical machining on Wikipedia, Youtube, Google News, Google Books, and Twitter on Digplanet. Electrochemical machining (ECM) is a method of removing metal by an electrochemical process. As far back as 1929, an experimental ECM process was developed by W.Gussef, although it was 1959 before a commercial process was established by the Anocut Engineering Company.
The ECM process is most widely used to produce complicated shapes such as turbine blades with good surface finish in difficult to machine materials. In deburring, ECM removes metal projections left from the machining process, and so dulls sharp edges. Because the tool does not contact the workpiece, there is no need to use expensive alloys or tempering procedures to make the tool tougher than the workpiece. There is less tool wear in ECM, and less heat and no stress are produced in processing that could damage the part. However, for a higher feed rate over a larger area, more current would be used, just like any machining processa€”removing more material faster takes more power. A fluid is used as a medium between the tool and the work piece (conductive for ECM and dielectric for EDM). The tool is fed continuously towards the workpiece to maintain a constant gap between them (EDM may incorporate intermittent or cyclic, typically partial, tool withdrawal).


Engine-makers today are finding a way around the problem of waste and multiple setups by using electrochemical machining (ECM) techniques.
Kennametal Precision Surface Solutions offers its Extrude Hone EVO next-generation electrochemical machining (ECM) platform featuring generator technology delivering between 3 and 100 kW of power, depending on machine configuration. ECM -- Electro-Chemical Machining is the generic term for a variety of electro-chemical operations.
The use of electrochemical machining (ECM) in the aerospace industry is well known for applications such as blades and blisks, but it requires considerable skill and experience to produce a viable electrode.
In fact all data suggests they formed at very high temperature rather than very cold temperatures. According to Patrick Matt, product manager at Kennametal Precision Surface Solutions, Precision Electrochemical Machining (PECM) is an electrochemical cavity-sinking erosion process with oscillating electrodes and a regulated working gap.
Its processes include electrical discharge machining and electrochemical machining of super alloy parts. It is normally used for mass production and is used for working extremely hard materials or materials that are difficult to machine using conventional methods.[1] Its use is limited to electrically conductive materials. The rise of EDM in the same period slowed ECM research in the west, although work continued behind the Iron Curtain.
As a result, the tools can be made from any cheap and easily machined, cast, or engraved electrically conductive substance.


Thus, for a small plunge cut of a 1 by 1 mm tool with a slow cut, only 0.1 amps would be needed. Depending on the work requirements, these machines are built in many different sizes as well.
The acronym ECM indicates that workpieces are machined by electrolytically dissolving metal.
Its product portfolio includes turbine blades and buckets, turbine shrouds and ring segments, and turbine vanes and nozzles.
ECM can cut small or odd-shaped angles, intricate contours or cavities in hard and exotic metals, such as titanium aluminides, Inconel, Waspaloy, and high nickel, cobalt, and rhenium alloys.[2] Both external and internal geometries can be machined.
High metal removal rates are possible with ECM, with no thermal or mechanical stresses being transferred to the part, and mirror surface finishes can be achieved. The original problems of poor dimensional accuracy and environmentally polluting waste have largely been overcome, although the process remains a niche technique.



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