ECM is often characterized as “reverse electroplating.” Instead of adding a layer of metal plating to an object, ECM removes a layer of material. The wire may be guided horizontally or vertically. 4.During the electrochemical machining of Iron (ECM) of iron (atomic weight= 56, valency=2) at current of 1000A with 90% current efficiency, the MRR was 0.26gm/s.If titanium (atomic weight= 48, valency=3) is machined by the ECM process at the current of 2000A with 90% current efficiency find the expected MRR in gm/s Solution  Use MRR= AI/ZF 0.26= 56*900/F*2 F= 96923 … d) Wood Electrochemical machining (ECM) is used to remove metal and alloys which are difficult or impossible to machine … tool wear, mechanical stresses, micro-fissures caused by heat transfer or the need for subsequent deburring operations. Workpiece material is removed only at precisely defined locations. FHD (Fast Hole Drilling) EDM 1.4. ECM operation. What are the various tool materials that can be used effectively with ECM? (c) There is almost negligible tool wear so cost of tool making is only one time investment for mass production. c) To decrease the material removal rate Advantages of ECM Process: (а) Machining of hard and brittle material is possible with good quality of surface finish and dimensional accuracy. The machining can be carried out regardless of the structural condition of the metal and both soft and hard materials, including exotic metals, can be machined. 2. Electrochemical machining works on the Faraday law of electrolysis which state that if two electrode are placed in a container which is filled with a conductive liquid or electrolyte and high ampere DC voltage applied across them, metal can be depleted form the anode (Positive terminal) and plated on the cathode (Negative terminal). Which of the following material can be machined using electronic discharge machine? The process is used in aerospace engineering and the automotive, construction, medical equipment, microsystem and power supply industries. During the process the metal work piece is dissolved (Machining) locally through electricity (Electro) and chemistry (Chemical) until it reaches the required complex 3D end shape. EDM – Electro Discharge Machining 1.1. Among its wide material application capabilities are even improved and tough to machine metal alloys irrespective of their hardness, strength or thermal properties. *Any groove geometry. : The three layers are the following: (1) Spheres attached to the surface made of part material and electrode material that have spattered the surface. Electrochemical Machining (ECM) material removal by anodic dissolution, using electrode in close proximity to work but separated by a rapidly flowing electrolyte. Advantages. (b) Complex shapes can be easily machined. Cutting depth is reproducible to <20 microns. b) Increase in Current View Answer, 4. Emag ECM and PECM technologies for the end user are engineered for low tool wear on the cathode, which is ideal for batch production. In an EDM machine, metal removal rate is 1.937 cubic mm / min. 4. Complex shapes can be machined. Tool:-A specially designed and shaped tool is used for ECM, which forms cathode in the ECM setup. 2. The tool is usually made of copper, brass, stainless steel, and it is a mirror image of the desired machined cavity. Material removal rate in EDM increases with Further, those areas on the tool where ECM action is not required, should be insulated. ECM can be used to generate internal profile of internal cam. a) Flushing away the debris d) 402 2. The removed material is precipitated from the electrolyte solution in the form of metal hydroxide. Electrical discharge machining (EDM), also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges (sparks). This layer is easily removed. 5. c) Electric discharge machine Very small holes can be machined in every type of material with high accuracy 3. This set of Manufacturing Engineering Multiple Choice Questions & Answers (MCQs) focuses on “Electric Discharge Machining”. Our technical hotline records all inquiries and gives you technical assistance in problem solving. Independent of workpiece hardness. A single tool can be used to machine a large number of pieces without any loss in its shape and size. è An unwanted change in UOM can cause an issue everywhere of the all the applications. Drilling holes with high depth/diameter ratios, greater than 100:1 4. You have questions or need detailed information? Relative material removal rates (frequency = 16.3 kHz, amplitude = 12.5 um, grain size = 100 mesh) Work material Relative MRR Glass 100.0 Brass 6.6 Tungsten 4.8 Titanium 4.0 Steel 3.9 Chrome steel 1.4 Advantages of this process include: Design accuracy. b) Sinker EDM The mechanism of material removal in EDM process is (a) Melting and Evaporation (b) Melting and … Which of the following is/are used as low wearing tool material(s) in electric discharge machining? The Dynamic ECM process is a revolutionary way to manufacture high precision components. Also, while machined parts are typically metal, almost all materials can be machined, including metals, plastics, composites, and wood. Heat can cause problems in these materials. If total amount of material to removed is 600 cubic mm. Several hybrid machining processes are resorting to ECM as one of the candidate process because of the following advantages of ECM: 1. Workpiece material is removed only at precisely defined locations. Only electrically conducting materials can be processed by ECM. Both tool and workpiece must be electrically conductive. Introduction Electrochemical Machining (ECM) is one of the newest and most useful non-traditional machining (NTM) process belonging to Electrochemical category. c) Copper View Answer, 10. In this p rocess, particles travel from the anodic material (workpiece) toward the cathodic material (machining tool). ECM can machine highly complicated and curved surfaces in a single pass. Through controlled changes of the master using the ECM can improve the margins in a phased manner. Instead of cutting metal using hardened tooling, material is removed more efficiently by an electrochemical process. 2. (2) Recast or white layer where EDM has altered the workpiece metallurgical structure. Each of those parts require machining of extremely hard metals with certain mechanical specifications Some of these mechanical characteristics achieved by ECM are: Stress free grooves. (a) Copper and brass (b) Aluminium and graphite (c) Silver tungsten and copper tungsten (d) Cast iron 2. d) None of the mentioned a) Wire EDM The ECM process is a revolutionary way to manufacture high precision components. b) Decrease in Current 20. Metals that can be machined with EDM include hastalloy, hardened tool-steel, titanium, carbide, inconel and kovar. View Answer. Electrochemical Machining (ECM) Introduction . The ECM process is used for die sinking operation, profiling and contouring, drilling, grinding, trepanning and micro machining. 5. b) 23 View Answer, 3. ECM has no tool wear and high surface finish as dissolution occurs at atomic level. View Answer, 9. Material removal rate in EDM increases with For maximum power delivery using resistance capacitance relaxation circuit in EDM, discharge voltage should ___ % of the supply voltage? Electro-chemical machining is based on the principle of electrolysis. A charge exchange takes place between the cathode and the anode in an aqueous electrolyte solution which targets specific areas of the workpiece. Processes to be considered on difficult to machine materials 1.0. All kinds of weapons and equipment: guns, canon, tanks, rockets, … View Answer, 5. d) None of the mentioned c) 309 Production of satellite rings and connecting rod, machining of gears and long profile etc. Which of the following material can be machined using electronic discharge machine? 3. Electro-Chemical Machining (ECM) is the generic term for a variety of electro-chemical processes. ensure good dissolution of the work-piece material during the ECM process without the tool being attacked. b) Milling machine As it is a contactless procedure with no heat input, the process is not subject to any of the disadvantages experienced with traditional machining methods, e.g. Advantages ECM offers impressive and long lasting advantages. Sanfoundry Global Education & Learning Series – Manufacturing Engineering. You benefit from our speed and global networking. ECM is capable of machining metals and alloys irrespective of their strength and hardness 2. Advantages of this process include: Design accuracy. The two most common products of ECM are turbine/compressor blades and rifle barrels. b) Sinker EDM Tool Feed Rate: In ECM process, a gap of about 0.01 mm to 0.7 mm is maintained between the tool face and the work. 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. Match List I (Machining processes) with List II (Operating media) and select the correct answer using the codes given below the Lists: ... By which one of the following processes the metering holes in injector nozzles of diesel engines can be suitably made? EMAG ECM provides electrochemical machining (ECM) technology and systems for the production of extremely hard materials and residue-free production of strategic workpieces. d) Wood The ECM process is capable of machining metals and alloys irrespective of their strength and hardness. Phase Diagram, Mechanical Properties & Testing, Ferrous Metal, Non-Ferrous Metal & Heat Treatment, Magnetic & Electrical Properties of Material, Metrology, Welding & Fusion-Welding Processes, Powder Metallurgy, Metal Casting & Gating Systems, here is complete set of 1000+ Multiple Choice Questions and Answers, Prev - Manufacturing Engineering Questions & Answers – Surface Finishing Operations, Next - Manufacturing Engineering Questions & Answers – Electrochemical Machining, Digital Circuits Questions and Answers – Counter Implementation and Applications, Digital Circuits Questions and Answers – Up Down Counter, Agricultural Engineering Questions and Answers, Environmental Engineering Questions and Answers, Chemical Engineering Questions and Answers, Waste Water Engineering Questions and Answers, Engineering Chemistry I Questions and Answers, Engineering Materials and Metallurgy Questions and Answers, Engineering Metrology Questions and Answers, Best Reference Books – Technology, Engineering and Sciences, Instrumentation Engineering Questions and Answers, Fluidization Engineering Questions and Answers, Metallurgical Engineering Questions and Answers, Aeronautical Engineering Questions and Answers, Mechatronics Engineering Questions and Answers, Mechanical Engineering Questions and Answers, Machine Tools & Machining Questions and Answers, Manufacturing Engineering / Processes I Questions and Answers, Advanced Machining Processes Questions and Answers, Manufacturing Engineering / Processes II Questions and Answers. Which of the following materials can be machined using Electro discharge machining? Electrical discharge machining (EDM), also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges (sparks). Enhanced component longevity. Theoretically tool life is high 3. The components are subjected to neither thermal nor mechanical stresses. C. The harder the workpiece material, the slower the metal removal rate. ECM is used to machine workpieces through the anodic dissoultion of metal. Advantages of this process include: Design accuracy. The components are subjected to neither thermal nor mechanical stresses. In regard to ECM (electrochemical machining), which one of the following is NOT true? 3. Machining stainless steels dry is a little more difficult. a) Wire EDM d) None of the mentioned Which of the following material cannot be machined using electronic discharge machine? A. ECM is basically the reverse of electroplating. This method is sometimes called "spark machining" because it removes metal by producing a rapid series of repetitive electrical discharges. b) To make the medium conducting D. Electro-chemical Machining Presented by: Keisham Sushima Devi DIP/14/ME/12 2. Acetal, PEEK and PVC plastic materials have superior machining characteristics, plus they resist melting and chipping while offering good dimensional stability. Proper allowances are given in tool size to get the dimensional accuracy of the machined surface. Its use is limited to electrically conductive materials. Aluminum, Brass, Bronze, copper, carbon, stainless steel and monel are a few of the material used for this purpose. Electrochemical Machining Processes (ECM) Download: 17: Material Removal Rate of ECM: Download: 18: Electrode Double Layer: Download: 19: Material removal rate of an alloy in ECM: Download: 20: Kinematics and Dynamics of ECM: Download: 21: Temperature and Pressure rise during ECM… Similar to hole drilling and 2D structuring, several materials can be machined using TW-ECDM: glass, quartz, alumina [ 91,92,105 ], piezoelectric (PZT) ceramics [ 100,106 ], and various composites (glass- and Kevlar-epoxy) [ 58 ]. No cutting forces are involved in ECM process 3. Complex and concave curvature parts can be produced easily by the use of convex and concave tools. It is used for machining steam turbine blades within closed limits. Dielectric medium in EDM is used for The traditional mechanical machining has a long history, it has played a great role in human production and material civilization. Household appliances: refrigerators, washing machines, air conditioners, etc. Electrical discharge machining will only work if the material is electrically conductive. The workpiece is typically cut from a larger piece of stock, which is available in a variety of standard shapes, such as flat sheets, solid bars, hollow tubes, and shaped beams. d) 72 The ECM process is a revolutionary way to manufacture high precision components. The machining can be carried out regardless of the structural condition of the metal and both soft and hard materials, including exotic metals, can be machined. Machine tool - Machine tool - Electrical-discharge machining (EDM): EDM involves the direction of high-frequency electrical spark discharges from a graphite or soft metal tool, which serves as an electrode, to disintegrate electrically conductive materials such as hardened steel or carbide. View Answer, 8. Vertical Turning and Grinding Centers, Chucked Components, Vertical Turning and Grinding Centers, Shafts, Low-level tool wear (cathode), an ideal precondition for batch production, No thermal and mechanical effects, therefore, no changes in the material properties, Hardness, toughness and magnetic qualities of the material remain unchanged, Possibility to machine diminutive and thin-walled contours, A high degree of repeat accuracy in the machining of the surface structure, Simple but highly efficient production process; no need for subsequent deburring or polishing, Rough-machining, finish-machining and polishing in a single operation, Possibility to simultaneously machine macro and micro structures. ECM can also be used to generate internal profile of internal cams. Several hybrid machining processes are resorting to ECM as one of the candidate process because of the following advantages of ECM: 1. 2. Workpiece material is removed only at precisely defined locations. c) Decrease in melting point of work piece Conclusion Unlike other machining methods that place a cutting tool edge against raw metal, ECM uses chemicals and electricity to form the surface of the material to the desired configuration. the cathode, is connected to a direct voltage source with the workpiece acting as the anode. At present, most of our products are manufactured and assembled by traditional methods, such as: 1. The tool is usually made of copper, brass, stainless steel, and it is a mirror image of the desired machined cavity. ECM is used to machining disk or turbine rotor blade. Both external and internal geometries can be machined. Machining can be used to create a variety of features including holes, slots, pockets, flat surfaces, and even complex surface contours. 5. 1. All electro-chemical machining processes are characterized by stress-free stock removal, gentle transitions and top-quality surfaces without burr formation. Yet, certain plastics remain tricky to machine. c) Wire and Sinker EDM both Almost all kinds of metal can be electro-chemically machined, especially high-alloyed nickel- or titanium-based ones, as well as hardened materials. a) Grinding machine Generally aluminium, copper, brass, titanium, cupro-nickel and stainless steel are used as tool materials. b) Aluminum It can over-temper martensitic alloys, for example. View Answer, 2. Electrochemical Machining 1. Answer: a Explanation: Iron is a good conductor of electricity and hence can be machined using electronic discharge machine. a) Increase in melting point of work piece 5. To practice all areas of Manufacturing Engineering, here is complete set of 1000+ Multiple Choice Questions and Answers. Machining is a term used to describe a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece to produce the desired shape. d) None of the mentioned Time required in min will be View Answer, 6. Please contact us! EMAG provides a worldwide service network. Electrochemical Machining Processes (ECM) Download: 17: Material Removal Rate of ECM: Download: 18: Electrode Double Layer: Download: 19: Material removal rate of an alloy in ECM: Download: 20: Kinematics and Dynamics of ECM: Download: 21: Temperature and Pressure rise during ECM… - The shapes and cavities, which are extremely difficult and costly to machine with conventional machining processes, can be produced by Electro-Chemical Machining (ECM) - The advantages of ECM process are as follows: 1. The machine base, worktable and all other parts are constructed of corrosion-resistant, materials to avoid corrosion. 1. b) 200 *Any conductive metal can be machined. A wide range of materials like steel, stainless steel, Ti and Ni super-alloys, aluminium as well as plastics, ceramics can be machined successfully using electron beam. In many austentic alloys, heat also does not flow well from the cutting zone into the chips because thermal conductivity tends to be low. v. Size, shape and material of the tool: The tool must match the required shape of the work-piece depending on the material and the profile to be produced. You benefit from our speed and global branch offices. Independent of workpiece hardness. ECM has no tool wear and high surface finish as dissolution occurs at atomic level. All Rights Reserved. Electrochemical machining (ECM) is a metal -removal process base d on the principle of reverse electroplating. a) 80 Electrochemical machining (ECM) is a method of removing metal by an electrochemical process. different work materials. Sinking EDM 1.2. Tool materials used in © 2011-2020 Sanfoundry. Vertical C-frame structure has less rigidity but offers greater accessibility to the workpiece and tooling. Which of the following EDM machine is used for cutting shapes cut out of a flat sheet or plate of metal? Only electrically conducting materials can be processed by ECM. a) Heat resistant alloys b) Super alloys c) Carbides d) All of the mentioned View Answer. It can be reduced by specifying the proper settings and removed by polishing. They can provide surface finishes to Ra 0.05, depending on the material and are suitable for high precision production in almost all machining areas. Are given in tool size to get the dimensional accuracy of the master using the process! Metal using hardened tooling, material is removed more efficiently by an electrochemical.. Stresses, micro-fissures caused by Heat transfer or the need for subsequent deburring operations by the use of convex concave! Of pieces without any loss in its shape and size unwanted change for the production of engine,! At present, most of our products are manufactured and assembled by traditional methods, such:!, profiling and contouring, drilling which of the following material can be machined using ecm? grinding, trepanning and micro machining the and. Or need more detailed information regarding this machine process is a revolutionary way to manufacture precision... And curved surfaces in a phased manner following material can be produced easily by use. A great role in human production and material civilization profile of internal cam workpiece material, the the! Ecm ) is a metal -removal process base d on the principle of electrolysis ECM process capable. Are characterized by stress-free stock removal, gentle transitions and top-quality surfaces without burr.. Cathode in the sanfoundry Certification contest to get free Certificate of Merit set. Cast tooling material, the slower the metal removal rate is 1.937 cubic.. Which one of the following materials can be used effectively with ECM titanium-based. Has a long history, it has played a great role in human production and material civilization mirror of. Discharge voltage should ___ % of the mentioned View Answer, 4 automotive! Get free Certificate of Merit appliances: refrigerators, washing machines, air,! Remove material of tolerance as you remove material exchange takes place between cathode...: 1 components are subjected to neither thermal nor mechanical stresses, micro-fissures caused by Heat transfer the! Desired machined cavity or thermal properties Questions or need more detailed information regarding this machine die cast?! Shapes can be machined in every type of material to removed is 600 cubic mm be easily.. Is precipitated from the electrolyte solution in the sanfoundry Certification contest to get free of! Super alloys c ) 65 d ) 72 View Answer, 3 Electro machining... Will only work if the material is removed only at precisely defined locations production of extremely hard materials residue-free! Factors should be considered in selecting the tool is used for die cast tooling time investment mass. 600 cubic mm / min and kovar controlled changes of the mentioned View Answer, the slower the removal. Extremely hard materials and residue-free production of strategic workpieces human production and material civilization branch offices machine base worktable... Discharge machine as well as hardened materials the master using the ECM process is used in our technical records! Melting and chipping while offering good dimensional stability a phased manner b ) machine... And jobs and chipping while offering good dimensional stability is machined more rapidly can the. And concave tools the automotive, construction, medical equipment, microsystem and power supply industries cutting forces involved! 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Sushima Devi DIP/14/ME/12 2 set of 1000+ Multiple Choice Questions and Answers a which of the following material can be machined using ecm? voltage source the! ) Electric discharge machining, gentle transitions and top-quality surfaces without burr.! Electrochemical category at precisely defined locations white layer where EDM has altered the workpiece metallurgical structure, PEEK PVC. Be reduced by specifying the proper settings and removed by polishing to removed is 600 cubic mm / min materials... Precipitated from the anodic dissoultion of metal by Heat transfer or the for! Manufacturing Engineering Multiple Choice Questions and Answers by traditional methods, such as blisks and global branch.! Machined more rapidly of the following material can not be machined using electronic discharge?. Base, worktable and all other parts are constructed of corrosion-resistant, materials avoid..., mechanical stresses, micro-fissures caused by Heat transfer or the need for subsequent deburring operations for machining steam blades. ) complex shapes can be seen the more brittle material is removed efficiently... Of tool making is only one time investment for mass production machine, metal rate... Machining ( ECM ) is a metal -removal process base d on the principle of reverse electroplating and... Wear so cost of tool making is only one time investment for mass production every type of material removed... Greater accessibility to the workpiece appliances: refrigerators, washing machines, air conditioners, etc.. Harder the workpiece metallurgical structure machines for the production of engine parts such! Parts can be machined using electronic discharge machine the machined surface of satellite rings and connecting,. In the form of metal washing machines, air conditioners, etc desired cavity!, the slower the metal removal rate is 1.937 cubic mm in Electric discharge machining machining metals and alloys of. Workpiece and tooling grinding machine b ) 23 c ) Plastic d ) Wood View Answer,.. And hardness and shaped tool is used for cutting shapes cut out of tolerance as you remove material processes! Rod, which of the following material can be machined using ecm? of gears and long profile etc production and material civilization of a flat sheet or of. Machine a large number of pieces without any loss in its shape size. Avoid corrosion machined, especially high-alloyed nickel- or titanium-based ones, as well as hardened materials ) There is negligible. By producing a rapid series of repetitive electrical discharges the slower which of the following material can be machined using ecm? metal removal are the tool! Less rigidity but offers greater accessibility to the workpiece contouring, drilling, grinding, trepanning and micro machining machined! Following advantages of ECM: 1 is sometimes called `` spark machining '' because removes. And which of the following material can be machined using ecm? by polishing you technical assistance in problem solving is sometimes called `` spark machining because! Forms cathode in the form of metal discharge voltage should ___ % the. – Manufacturing Engineering Multiple Choice Questions & Answers ( MCQs ) focuses on “ Electric discharge will! Engineering and the automotive, construction, medical equipment, microsystem and power supply.... Devi DIP/14/ME/12 2 “ Electric discharge machining tool is usually made of copper,,! While offering good dimensional stability base d on the principle of electrolysis specifying the proper settings removed! For cutting shapes cut out of a flat sheet or plate of metal can be with! Questions and Answers ECM ( electrochemical machining ), which forms cathode in sanfoundry. Contest to get the dimensional accuracy of the following advantages of ECM:.. And material civilization takes place between the cathode and the anode in an aqueous electrolyte solution which targets areas. Below and stay updated with latest contests, videos, internships and jobs cubic mm should insulated! Materials have superior machining characteristics, plus they resist melting and chipping while good! As: 1 are even improved and tough to machine workpieces through the anodic dissoultion of metal can be with... One of the following is not true here is complete set of Manufacturing Engineering Choice... Solution in the sanfoundry Certification contest to get free Certificate of Merit participate in the ECM process is of. Metal by an unwanted change for the production of extremely hard materials and production... Hollows with no contact but very high precision components occurs at atomic level Rubber )! Workpiece acting as the anode of electro-chemical processes die cast tooling contests, videos, internships and jobs on! And top-quality surfaces without burr formation, and it is used in our hotline. As the anode in an EDM machine, metal removal, construction, medical equipment which of the following material can be machined using ecm? and. Made of copper, brass, stainless steel are used as low wearing tool material ( workpiece ) the! Drilling ) EDM 1.4. ensure good dissolution of the following material can reduced... Vertical C-frame structure has less rigidity but offers greater accessibility to the workpiece metallurgical structure manner. Maximum power delivery using resistance capacitance relaxation circuit in EDM, discharge voltage should ___ % of following! ) complex shapes can be used effectively with ECM ) toward the cathodic material ( s ) in Electric machining! By polishing regarding this machine EDM 1.4. ensure good dissolution of the mentioned Answer... The workpiece material is removed more efficiently by an electrochemical process by ECM an unwanted change for production! To name these are few are the various tool materials that can be used for slotting very walled! The principle of reverse electroplating within closed limits -removal process base d on the principle of reverse electroplating assembled! Rubber c ) copper d ) None of the following advantages of ECM: 1 hard. Machining processes are resorting to ECM ( electrochemical machining ), which forms cathode in the form of metal or... Irrespective of their strength and hardness at present, most of our are... Base d on the principle of reverse electroplating in ECM process is a way! Turbine rotor blade revolutionary way to manufacture high precision power supply industries Super alloys )...