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ECM / PECM Technology Polishing, Deburring, 3D Contouring


EMAG ECM GmbH Complete solutions, design and development, prototype manufacture, advisory service. Your contact for all questions on electro-chemical machining.

E C M P E C M

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E L E CT R O- C H E M I C A L M A C H I N I N G

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The process.

The electro-chemical machining process

of the metal’s microstructure and

is based on the principle of electrolysis.

regardless of whether the material

An electrode connected to a D.C. source

is soft or hard. The components are

acts as cathode (the tool). The workpiece

exposed to neither thermal nor

represents the other electrode and

mechanical stresses.

is poled as anode. In a watery electrolyte solution the cathode and workpiece exchange a charge that machines the workpiece – without touching – at the selected point, generating contours, annular grooves, flutes or cavities – all with the highest precision. The material being removed separates from the electrolyte solution as metal hydroxide. Machining is accomplished irrespective

E C M P E C M

Cathode Electrolyte Workpiece

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Power source


The different machining operations.

ECM – Electro-Chemical Machining

PECM – Precision Electro-Chemical Machining

Stationary cathode

Cathode with infeed and mechanical oscillation

Operation

Technologies

Operation

Technologies

Deburring

DC (Direct Current)

Precision profile

Pulsed ECM

or pulsed ECM Polishing

Pulsed ECM

Recessing the surface

Pulsed ECM

Cavity

DC or pulsed ECM

Cathode with infeed Operation

Technologies

Drilling

DC or pulsed ECM

2.5D countersinking

DC or pulsed ECM

Cavity in an injection nozzle

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Electro-Chemical Machining – Great precision and cost-effective.

ECM – Electro-Chemical Machining

with traditional machining methods,

is the generic term for a variety of

e.g. tool wear, mechanical stresses,

electro-chemical processes. ECM is

micro-fissures caused by heat transfer,

used to machine workpieces by

surface oxidation or the need for

electrolytically dissolving the metal.

subsequent deburring operations. All

The process is used in aerospace

electro-chemical machining processes

engineering and the automotive,

are characterized by stress-free stock

medical equipment, microsystem and

removal, gentle transitions and smooth

power supply industries. Almost all

surfaces without burr formation.

kinds of metal can be electro-chemically machined, even high-alloyed nickel- or titanium-based ones, as well as hardened materials. As it is a contactless procedure with no heat input, the process is not subject to any of the disadvantages experienced

E C M P E C M

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The advantages of Electro-Chemical Machining •• Low-level tool wear (cathode), an ideal precondition for batch production •• Surface finishes of up to Ra 0.05 •• Precision machining •• No thermal and mechanical effects, therefore, no changes in the material properties •• Hardness, toughness and magnetic qualities of the material remain unchanged •• Possibility to machine diminutive and thin-walled contours •• A high degree of repeat accuracy in the machining of the surface structure •• Simple but highly efficient production process; no need for subsequent deburring or polishing •• Rough-machining, finish-machining and polishing in a single operation •• Possibility to machine superalloys •• Possibility to simultaneously machine macro and micro structures

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ECM system BI smart.

On the ECM Standard Machining System BI smart the operator loads and removes the workpieces from the ECM unit by hand. A two-handed control button operation activates the ECM process that carries out the deburring operation.

E C M P E C M

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A plastic construction with a stainless steel frame and ergonomically arranged manual workstation offers a solid basis with the following standard equipment: •• Siemens touch-screen panel •• Scalable generator technology •• Conductance monitor •• Temperature control •• pH-value control with acid metering •• Machining area: 900 x 700 mm •• Two-handed control button operation Optional equipment available upon request

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ECM system CS / CI.

The CS / CI represents the optimal

The CS / CI contains as standard:

introduction to the automation of ECM processes.

•• Siemens touch-screen panel •• Scalable generator technology

•• Modular machine concept

•• Conductance monitor

•• Intelligent software and

•• Temperature control

hardware interfaces •• Starting with manual / semiautomatic operation •• The system can quickly be upgraded to full automation

•• pH-value control with acid metering •• Quill clamping surface: 1,150 x 950 mm •• Quill stroke with safety interlock •• Two-handed control button operation •• Automation interfaces included

E C M P E C M

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The CS stand-alone machine forms the basis of a modular automation concept. It saves on capital outlay, as further investment is only required when an increase in production calls for the link-up of a number of processes (e.g. pre-cleansing, ECM station 1, ECM station 2, secondary treatment).

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PECM system PT smart.

PECM system with modularly upgradeable tool concept for

•• Graphic visualization with ergonomic operator interface

sophisticated 2D and 3D structures.

•• Scalable generator technology with

•• Machine base made of steel / natural

•• Pulse frequencies of up to 100 kHz

up to 5,000 A pulsed power stone design •• Machining area: 500 x 500 x 500 mm (W x D x H) •• Clamping plate: 250 x 250 mm •• Footprint: 1,200 x 1,200 x 2,200 mm (W x D x H) •• Clamping plate with M10 thread with 50 mm hole grid •• High degree of positioning accuracy •• Precision oscillator •• Optional: XY table •• Optional: rotary table as C-axis

E C M P E C M

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•• Complex filter processes


PECM system PT.

PECM system with modularly upgradeable tool concept for sophisticated 2D and 3D structures. •• Machine base made of MINERALIT® •• Clamping surface: 800 x 450 x 660mm (W x D x H) •• Machining area: 1,250 x 800 mm (W x D) •• Footprint: 1,500 x 2,200 x 3,500 mm (W x D x H) •• High degree of positioning accuracy •• Precision oscillator •• Optional: XY table

•• Scalable generator technology with up to 40,000 A pulsed power

•• Optional: rotary table as C-axis

•• Pulse frequencies of up to 100 kHz

•• Graphic visualization with ergonomic

•• Complex filter processes

operator interface

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PECM system PO 900 BF.

PECM system for complex metalworking applications.

•• Graphic visualization with ergonomic operator interface •• Scalable generator technology with

•• Machine base made of Mineralit® in bed design •• Compound slide with adapter for paddle wheel with Z-, Y-, B- and C-axes •• Machine cover panels in stainless steel •• Component diameters of up to 900 mm •• Workpiece weight max. 500 kg •• High degree of positioning accuracy •• Freely programmable precision oscillator

E C M P E C M

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up to 30,000 A pulsed power •• Pulse frequencies of up to 100 kHz •• Complex filter processes


Electrolyte management.

The filter concept used is ultrafiltration.

Technical Data:

The electrolyte is cleaned by a backflushable filter membrane. The concentrated

•• Electrolyte NaNO3 or NaCl

slurry from the backflushing process is

•• Flow rates of up to 1,000 l/min

filtered using a chamber filter press.

•• Electrolyte pressures of up to 20 bar

Optimum electrolyte quality is ensured

•• Temperature control, electrolyte temperature: 20-40°C ± 1°C

and the hydroxide slurry to be disposed

•• pH-value control with acid/base metering, pH 7-8

of is reduced thanks to effective

•• Particle size: < 1 μm

compression. Cleaning the chamber

•• Visualization and setting of all electrolyte parameters using

filter press with a jet of compressed air

the 10” touchscreen panel

minimizes the amount of liquid (electrolyte and salt) in the sludge and optimizes consumption and waste disposal costs of the system.

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Technical Data.

Capacity

BI smart

CS

CI

Machining area

mm

900 x 700

1,150 x 950

1,150 x 950

Vertical travel

mm

300

300

Power rating / equipment specification DC Pulsed

V / A 30 – 60 / 200 – 5,000 30 – 60 / 200 – 5,000 30 – 60 / 200 – 5,000 A

max. 20,000

max. 20,000

max. 20,000

NaNO3 / NaCl

NaNO3 / NaCl

NaNO3 / NaCl

possible

possible

possible

NC drive

option

option

Retraction unit

option

option

Extraction system

option

option

–*

3,400

Electrolyte Operating pressure

bar

Automation

10

10

10

Measurements Length

mm

3,000

Width

mm

1,800

–*

2,000

Height

mm

2,700

2,700

2,700

l

Electrolyte supply 1,000

1,000 – 2,700

1,000

Temperature measurement

yes

yes

yes

pH-value measurement

yes

yes

yes

Conductance measurement

yes

yes

yes

Acid replenishment

yes

yes

yes

Cooling system

yes

yes

yes

Tank

Filtration

Chamber filter-press / microfiltration / filter cartridge **

* dependent on installation ** dependent on application Measurements l

1,000

1,600

2,700

Side A

mm

2,100

3,100

3,500

Side B

mm

1,150

1,150

1,750

Tank capacity

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Manual machining

IV

I

II

V

III

Loading by robot

IV

I

- ECM machine

II

- Electrical cabinet

III

- Machining area

IV

- Secondary cleaning

V

- Secondary preservation

VI

- Preliminary purification

VII

- Robot

VIII

- Linear handling system

V

VII

I

II

III

VI

Loading with linear handling system

I

II

VIII

VI

III

IV

V

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Technical data.

Floor plan CI Dimensions in mm

3,369

967

2,728

1,340

2,475

1,871

3,374

Floor plan CS Dimensions in mm

937

2,728

1,340

1,340

B

2,544

A

2,578

Subject to technical changes

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Floor plan PT

3,259

Dimensions in mm

1,368

2,317

Floor plan PO 900 BF Dimensions in mm

4,200

3,972

2,427

6,421

Subject to technical changes

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236-1-GB/05.2012 · Printed in Germany · © Copyright EMAG ·

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Electro-Chemical Machining