B. S. Brar Et Al. (1) Have Discussed About Developing A Hybrid Process

B. S. Brar et al.
[1] have discussed about developing a hybrid process

of Electrochemical machining(ECM) and abrasive flow
machining(AFM) for finishing internal holes/slots or cavities having
prismatic sections. He achieved finishing on work piece by applying
low voltage DC supply across electrolyte-abrasive laden media
flooded gap and prismatic rod as cathode and work piece as anode.
By this material removal rate(MRR) was increased because of
material removed by both controlled anodic dissolution(ECM) at
atomic level and abrasive machining. He conducted experiments by
taking work piece of yellow brass ( 65% Cu, 35% Zn, 156BHN
hardness) and observed that MRR increases with increase in supply
voltage. An improvement of 87.43% in surface roughness(∆R a) was
observed at 10V with final surface roughness value of 0.49 µm from
4.02 µm. The limitation of this process is it can only be applied to
prismatic geometries because of cathode-electrode requirement
along with anode-work piece.
Silva Neto et al. [2] have developed an electro chemical machining

(ECM) prototype in laboratory using simple components in which
coupled motor rotation in tools reducer determines the feed rate. He
conducted experiments by taking work piece made of SAE-XEV-S
valve steel and tool made up of electrolytic copper. The experiment
was carried out using two different electrolytes, they are sodium
chloride electrolyte with concentration 100 g/l ,and sodium nitride
with concentration of 250 g/l at flow rate of 300 L/hr . He studied
relation between different process parameters and concluded that as
feed rate increases the material removal rate increases up to certain
time and also as feed rate increases gap between tool and work
piece continuously reduced. And also he found that MRR is affected
by the type of electrolyte and MRR is more with NaCl electrolyte
because of its higher current efficiency.
Claudia Richter et al.[3] studied on application of Electrochemical
Polishing(ECP) for polishing complex 3D micro devices manufactured
using µEDM process. He stated that instead of obtaining better
surface properties by optimising process parameters in µEDM
process, it is desirable to improve surface properties using ECP. To
study about parameters affecting surface properties he used two
electrolyte solutions, they are H3Po4(85%) and H2So4(90%) with two
volume ratios 3:2 and 2:1. He conducted experiments on straight
micro channels made of Stainless steel (X10CrNi18-8) along with
effect of glycerol in electrolyte. He concluded that the surface
roughness of Ra,EP=(22.14 ±1.25)nm is achieved from Ra,EDM=(94.92
±0.99)nm at I=600 mA , 3:2 volume ratio of H3Po4 and H2So4 and
glycerol volume content of 20%. This is 90% improvement compared
to the results of µEDM process.
J.C.Fang et al.[4] reported that the finishing efficiency of

electrochemical polishing can be increased by application of
magnetic field. He conducted experiment with acidic electrolyte,
steel work piece and copper cathode at 70oC.He studied effect on
efficiency, material removal rate and surface roughness by
application of magnetic field. He concluded that application of
magnetic field has more effect on rough surfaces compared to
smooth surfaces and finishing efficiency is increased. He reported
that magnetic field alters electrochemical reactions and increases
inter electrode current density because of which material removal
rate increases. So for magnetic electrochemical polishing optimum
matching principal parameters (like magnetic intensity, voltage, gap)
should be selected for better results.
References:
[1] B.S.Brar , R.S.Walia , V.P.Singh , “Electrochemical-aided abrasive
flow machining (ECA2FM) process:a hubrid machining process” , Int
J Adv Manuf Technol , DOI:10.1007/s00170-015-6806-y
[2] Silva Neto , Joao Cirilo da , “Development of a prototype of
electrochemical machining” ,Advanced Materials Research Vol 223
(2011) pp 940-949
[3] Claudia richter ,Thomas Krah , Stephanus Buttgenbach “Novel 3D
manufacturing method combining microelectrical discharge
machining and electrochemical polishing” ,Microsyst technol(2012)
18:1109-1118
[4] J.C.Fang , Z.J.Jin , W.J.Xu , Y.Y.Shi “Magnetic electrochemical
finishing machining” , Journal of materials processing technology
129(2002) 283-287

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B. S. Brar et al.

[1] have discussed about developing a hybrid process

Silva Neto et al. [2] have developed an electro chemical machining

J.C.Fang et al.[4] reported that the finishing efficiency of

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