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ECM - Advantages and disadvantages

The ECM process has many advantages as regards to other machining techniques. These can be divided in machine, material and product.

Machine advantages:

• Low running and tooling costs.
• Initial investment in tooling is high, but the recurring costs are low.
  • o?electrode wear.

:

• The hardness, toughness and thermal resistance do not effect the Material Removal Rate (MRR). For tooling the product it is also not important if the tooling occurs before or after a hardening step.
• MRR is high, approximately 1,5 cm³/min at 1000 A DC.
• MRR does not depend on the type of material.
  • Hard and tough alloys are equally quick machined as for instance Aluminium.

:

• The product is after tooling free from burrs.
• Contact free tooling principle.
  • The process gets no thermal or physical tension in the product.
  • No upper layer deformation like in other machining techniques.
• 3-Dimensional products can be tooled in one single step.
• High surface qualities are feasible (Ra <0,05>
• High dimension accuracy is feasible.
• Material tension which is released during the process, is being counterbalanced if possible.
• Stainless steel is influenced in its upper layer by various machining techniques, by which local rust formation can occur. This does not happen with ECM.
• With the application of ECM, it is possible to generate more freedom of design for the product.

ECM is a technique with high machining speeds and relatively low costs.

Together with the many advantages, ECM had also a few disadvantages:

Disadvantages:

• ECM is known from the past as an environmental polluting process. With the development in the treatment of electrolyte, this process is less environmental polluting. By realising a closed electrolyte treatment system, the disposals in the sewage system are shut off. The produced sludge nowadays can be used as raw material with or without after-treatment. This depends on the machined material.
• Each product and each material demands a new research.
• High production numbers are necessary because a special electrode has to be developed for each product. The optimum depends on the complexity and the material.
• High energy consumption, but much lower than other non-conventional machining techniques.
• The electrode design is complex and initially expensive, but it has an nfinite?service life.
• ECM demands a staff with a relatively high level of knowledge.

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