ABSTRACT
Electrochemical machining (ECM) is a process that relies on the principle of electrolysis for material removal. ECM is most often applied when shaped cavities are machined into alloys that are difficult to shape by conventional methods. The amount of overcut that occurs at the sides of the ECM tool is dependent upon the feed rate. A low feed rate will produce a large overcut, and conversely, a high feed rate will reduce the amount of overcut. The very solid construction is necessary to withstand deflection while containing the forces generated by the high electrolyte flow. Operators are protected by automatically operating plexiglass shields that seal the machine work chamber during the ECM cycle. The function of the electrolyte in ECM is to act as a conductor to carry current, to remove the products of the electrochemical reaction from the gap, and to remove the heat generated by the process.
