Abstract

Electrochemical machining (ECM), a metal removal process based on the laws of electrolysis, was developed for shaping high strength heat-resistant alloys that are difficult to machine by conventional techniques. Using ECM techniques, hard metals can be shaped as reliably as soft ones and the rate of machining does not depend on hardness. Because the tool electrode used in the process does not wear, soft metals can be used as tools to form shapes on harder workpieces. Other applications include deburring, hole drilling, electrochemical grinding, and removal of fatigue cracks in steel structures. The working principles of ECM are described along with the types of electrolytes used. Parameters for various metals are discussed.