Electro Chemical Machining (ECM)

Electro Chemical MachiningPM-PRECISION’s ECM technology is highly suitable for products with a complex 3D geometry in steel and high alloys. ECM is also excellent for products where upper-layer deformations due to more conventional machining techniques are not accepted, as for example is the case with spark erosion.

Replica accuracy is increased by reducing the working gap which is in turn made possible by the PEM process. This makes it possible to manufacture significantly smaller structures and shapes such as prongs, drilled holes, cavities and inscriptions can be easily produced. Simultaneous production of rough and very fine highly-complex structures is also possible. On account of the complex machining process, the electrodes demand a different approach to the one applied in electrical discharge machining processes. Sufficient purging of the effective gap must be observed when designing and manufacturing the electrode. Additionally, a purging chamber may be required in order to retain the electrolyte in the working gap.

Electro Chemical Machining (ECM) process advantages

process advantages

  • No micro cracks
  • Burr free process
  • Accurate geometry reproduction
  • Non-contact machining process
  • No process-related electrode wear
  • Repeatability accuracy (+/- 2-5 μm tolerance)
  • Processing independent of material hardness
  • No temperature change in the material structure
  • Roughing, finishing and polishing in one work step
  • Components are not subjected to mechanical loads
  • Thin-walled structures can be produced / processed
  • Surface finish of Ra => 0,03 µm a single surface possible
  • Magnetic characteristics of the product are not influenced
  • Machining of practically all materials that are electrically conductive
  • High feed rates of up to 0.5 mm/min. independent of the cavity area
  • One electrode can be used to produce infinite number of identical parts
  • Suitable for small and larger series as well as the manufacture of prototypes
  • Machining of superalloys and powder-metallurgical steels (Nimonic, Stellite, Incoloy, Monel)
  • No microstructure modification on the product as no process-related thermal or mechanical loads evolve
  • Short machining times: feed rates between 0,1 and 1,8 mm per minute can be realized depending on material / application / surface area

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