ECM Processes
	Demonstrations and Literature ECM FAQ's Deburring Solutions Surface Finishing Solutions

As an electrolytic solution (water and specialized salts) is pumped over the workpiece surface, a DC current flows between the tool and the workpiece. The amount of material removed is determined by the amount of electrical current flowing between the negatively charged tool and the positive charged workpiece. The tool is normally designed to have a mirror image of the final surface of the workpiece.

Since the tooling, known as a cathode, never touches the workpiece, there is virtually no tool wear in the process. Typical deburring and polishing times are extremely fast -- 10-30 seconds for most applications. Depending on production requirements and the workpiece size, multiple part fixturing can be used to obtain high production rates.

ECM, ECD, and ECP are essentially the same process but used to achieve slightly different results or objectives.

ECM is the machining of unique contours or specific edge geometries that normally cannot be produced by conventional machining methods. Classic examples are the internal galleries of diesel fuel injector nozzles, anti-lock brake system components, and rifling inside gun barrels.

ECD is deburring of holes and edges in difficult to reach locations on a workpiece. Examples include drilled break-through holes on the interior surface of air bag propellant systems and cross-drilled holes inside manifold blocks.

ECP is the high quality polishing of contoured surfaces. Examples include the external surfaces of stainless steel and cobalt chrome knee replacements.

Components requiring edge radius conditions and other performance criteria often are produced most economically with the electrolytic process. Applications vary from full-contour radiusing (such as pinion gears) to a continuously varying radius as produced on conic surface intersections. Edge radii, measuring from a few thousandths of an inch to a few hundredths of an inch, can be produced repeatedly with cycle times of 30-90 seconds.

Electrolytic surface quality enhancement is applied to surfaces that are cast, machined, or EDM'd. Material removal ranging from 0.0005 inch to 0.01 inch with a 5-10 surface roughness improvement factor is realized in most applications. Typical applications include surgical implants, glass molds and various stainless steel components. Significant surface brightening usually accompanies smoothing of the surface texture. Surface finish often is an additional benefit of deburring as seen in many surgical components

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