Electrochemical machining is a depleting process, based on Faraday’s law of electrolysis. Workpiece works as an anode and tool acts as a cathode. The tool material used is copper and brass. Sometimes stainless steel is also used as a tool material. The tool used is hollow through which electrolyte is pumped at high pressure as shown in Figure 23.5. There is a small gap of 0.1–0.2 mm used between the tool and work surface and tool is fed into work. High flow of electrolyte is maintained to avoid the deposition of work material on the cathode, i.e., tool. The current used is of few thousand amperes and voltage ranges between 8 and 20 V. The material removal rate is (approx) 1,600 mm3/min for each 1,000 A and it is independent of work hardness.
Figure 23.5 A Conceptual Diagram of Machining by ECM
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