What is Electrochemical Deburring

Electrochemical machining was first applied in the early 1900s. Until 1929, experiments were conducted. The use of electrochemical energy to remove metal became widespread and commercialized in 1956 with the introduction of electrochemical machining.

There are various types of deburring, including manual, punch, Electrochemical, tumbling, and thermal deburring. Today, here in this post, we will explain the Electrochemical deburring process. Although the precise history of electrochemical deburring is known, we can infer that burrs after machining had to be disposed of due to the increasing demand for precise products.

In order to get better-finished goods, electrochemical machining led to the development of electrochemical deburring as a subfield.

ELECTROCHEMICAL DEBURRING: WHAT IS IT?

In order to create a smooth final surface, burrs must be removed from any workpiece's source. This process is known as deburring. The energy source utilized for deburring is referred to as electrochemical. Altogether, the term "electrochemical chemical deburring" describes a machining technique that uses electrochemical energy to remove burrs.

For this operation, a specialized instrument known as a deburring tool is utilized. The deburring tool and the workpiece do not come into contact during electrochemical deburring, just like in any other electrochemical operation.

It functions like an electroplating process in reverse. The workpiece serves as the anode and the tool serves as the cathode in electrochemical deburring.

The workpiece and the tool are maintained in a flowing electrolyte liquid. Because electrolytes are used, ECD is often referred to as electrolytic deburring. It is a quick and simple procedure.

NEED OF ELECTROCHEMICAL DEBURRING

In many businesses that deal with high accuracy, burr removal is seen as a major issue.

• It is crucial to eliminate burrs since they might occasionally have sharp edges that could injure workers or the operator.
• The mating parts' surface may crack as a result of it. When the area of contact shrinks, pressure rises.
• Additionally, the workpiece's beauty is diminished.
• Hard metal deburring also requires the use of electrochemical deburring.

PARTS OF ELECTROCHEMICAL DEBURRING

The following are various elements or sections of an electrochemical deburring setup:

• SUPPLY TANK – A supply tank is a tank that holds electrolytes for the system's supply.
• PUMPS – P1 and P2, two pumps, are present. Electrolytes are supplied to the reaction tank via P1, and the electrolytes are supplied from the collection tank to the supply tank via P2.
• COLLECTION TANK – A collection tank is the container used to hold filtered electrolytes.
• REACTION TANK – Reaction tanks are spaces or containers that hold the tool-workpiece and electrolyte. Within the reaction tank, the workpiece and tool undergo an electrochemical reaction. The tank's construction ensures that electrolytes are always flowing through it to transport the slag.
• DC POWER SUPPLY – The DC power supply utilized for electrochemical deburring has modest voltage values. However, because the current value is high, the metal is removed from the workpiece's surface more quickly.
• BASE – Here, the workpiece is kept stable by the conducting substance used to make the base. The two workpieces are electrically connected by the base as well. The base that joins the two workpieces receives a DC supply.
• ELECTROLYTE – A basic salt and water solution serves as an electrolyte. Typically, it is a conductive solution of sodium nitrate and chloride in water. For use in general water, nitrate, and sodium are combined in a 2:1 ratio. For optimal effects, the electrolyte temperature is kept at 20 degrees Celsius. For metals like titanium, a combination of salts is utilized.
• TOOL – The most crucial element of an electrochemical deburring system is the tool. Different tools are used for different purposes.

It is composed of an externally insulated conductometric. When the tool is linked to the DC power supply's negative terminal, it functions as the cathode.

Keep the distance between the workpiece and the tool between 0.5 and 1 mm. The following is the general process for designing an electrochemical deburring tool.

• Assuming the burr is 2 mm tall and the workpiece is 15 mm tall.
• The tool must therefore be developed so that it has a height of more than 15 + 2 = 17 mm.
• It needs to be insulated up to 15 mm so that the burr is removed when the material is removed above 15 mm.

THE ELECTROCHEMICAL DEBURRING PROCESS

It is necessary to comprehend the electrochemical deburring operating principle before beginning any operation. 

Reverse electroplating is the basis for how electrochemical deburring operates. The quantity of metal moved is precisely proportional to the electric current, according to Faraday's equation for electrolysis. Material removal from the workpiece to the tool occurs when an electrochemical deburring setup is subjected to a high current. The space between the tool and the workpiece is where removal occurs. The material flows away as a result of the electrolyte's flow rather than being deposited on the tool. A highly polished surface is achieved by this method.

WORKING IN STAGES:

STAGE 1: The tool is placed between the workpieces, with the workpiece remaining on the base.

STAGE 2: The workpiece is linked to the DC power supply's positive end. Additionally, the tool is linked to the DC power supply's negative terminal. The electrolyte flow is initiated and the pump is turned on.

STAGE 3: The electrolyte travels through a filter before entering the reaction tank. Following the activation of the DC power source, the reaction begins.

STAGE 4: Between the workpiece and the electrolyte, there is an electron transfer. Burrs on the workpiece's surface are removed as a result of electron transfer.

STAGE 5: The residual electrolyte is forced to enter the collection tank via the filter (F2). The electrolyte is once more fed to the supply tank from the collection tank. And the procedure is carried out once more.

STAGE 6: The workpiece is removed and the power supply is turned off after the burr has been removed.

BENEFITS OF ELECTROCHEMICAL DEBURRING

The benefits of electrochemical deburring include the following:

• Excellent surface finish is achieved by the highly precise technique of electrochemical deburring.
• There is very little heat generation.
• The workpiece has not acquired any thermal stresses.
• Tool wear is nonexistent.
• There is greater efficiency.
• A quicker process boosts the plant's output.
• Goods are produced.

DRAWBACKS OF ELECTROCHEMICAL DEBURRING

The following are drawbacks or demerits:

• High equipment purchase price.
• For different workpieces, different tools need to be devised.
• Intricate procedure.
• An extremely competent operator is needed.
• It is only possible to manufacture workpieces that conduct electricity.

USES FOR ELECTROCHEMICAL DEBURRING

• Gear deburring is done with it.
• Moreover, it is employed to remove sharp edges from extremely precise machinery.
• Be applied to hard materials to refine their surfaces as well.