History
From machining technique to versatile ECM technique
Electrochemical Machining is a relatively old machining technique whose basis was laid way back in the 19th century. Michael Faraday, the greatest researcher of all time (1791-1867), discovered the principles of anodic metal machining.
This discovery by Faraday has also laid the foundation for the better known electroplating and electro polishing techniques, commonly applied today in the industry worldwide.
1920-1960
In 1929 the Russian researcher W. Gussef developed a process to machine metal anodically. Many years later in 1941, Burgess appeared with a publication in the Electrochemical Society. In the autumn of 1959, Anocut Engineering Company established the anodic metal machining technique as a commercially suitable technique. SIFCO (Steel Improvement and Forge Company) followed with a commercial application one year later.
1960-1970
The technique was applied in several ways as a machining technique in the 60’s and 70’s. In particular the gas turbine industry used the technique frequently. Electrical discharge machining was also deep in development during this period, which at the time was a more accurate technique and was preferred over the ECM technique, being less accurate and its waste putting a strain on the environment. On the other hand, electrochemical machining was able to achieve much higher machining speeds.
The versatility of today’s ECM technique
Nowadays various companies are using the ECM technique, a technique that can hardly be compared to the anodic machining technique it once was. Where in the past the technique lost on accuracy and environmental strain, today’s ECM technique is greatly optimised using the latest of technological development.
- Development of vibrating axes has enabled machining with a process gap of <5 micrometer. By being able to control and maintain a minimal gap high accuracy can be achieved.
- Vibrating axes where a rinsing cycle is integrated into the process for the disposal of reaction products require an accurate pulsating power supply being able to make microsecond pulses in combination with a high current (>1000A).
- Electrolyte regeneration (micro filtration) has enabled the cleaning of the electrolyte to a ppm level and can therefore be reused indefinitely. The produced sludge can often be recycled, depending on composition.
The technique can be applied to a variety of metal products in the automotive, aerospace, medical, jewellery industry, printing industry, textile industry, energy industry and various other sectors. The technique is also frequently utilized for very specific micro applications.