Electrochemical grinding process-
What is electrochemical grinding?
What is the significance of this electrochemical grinding? What are the advantages and disadvantages of electrochemical grinding? You can get an answer to the following questions. First of all, you can get to know the process involved in electrochemical grinding and will be further continued with significance, advantages and disadvantages of electrochemical grinding process.
Electrochemical grinding mainly consists of a grinding wheel, nozzle, spindle, contact brushes, work piece, fixture, machine table, tank, electrolyte and gap between the grinding wheel and the fixture of the material for the grinding to take place. The improvement of electrochemical machining process depends on many factors which include the quality of grinding wheel, the speed of electrolyte coming from the nozzle, the quantity of electrolyte coming from the nozzle, spindle speed, the quality of contact brushes, type of work piece material to be used, the size of tank and lastly type of electrolyte. Through these conditions the electrolytic process is developed. In this process the removal of material takes place by electrochemical deposition as well as material abrasion. For instance, a work piece is working under electrochemical grinding process, then the amount of material removed by electrochemical deposition will be 90% and the amount of material removed through material operation will be 10%. The spindle of electrochemical grinding contains bearings in it. The bearings are not the type used in automobile. There are many different types of bearings and are mentioned in the post mentioned below.
Due to the rotary motion of the spindle, the grinding wheel 38 since it is supported by the spindle. Contact brushes are fixed to the spindle since it is the main base. The work piece which is placed on the material table, can be moved in to and fro motion. An insulating sleeve is used in the spindle and grinding wheel for the provision of insulation. A DC power supply the current from cathode to anode and electrolyte flows from the tank to the place where distance is maintained between the wheel and the work piece through nozzle. In the electrochemical grinding process, Cathode is the grinding wheel and anode is the work piece. As the current flows from wheel to the work piece, electrochemical oxidation is found on the work surface. This oxidation film is removed by the grinding wheel and this type of material removal is known as electrochemical grinding process. Thus a precise and finished surface is obtained with the help of electrochemical grinding process.
Significance of electrochemical grinding process-
Electrochemical grinding uses a special type of material removal by oxidation. The material to be removed is first subjected to oxidation and then it is removed with the help of grinding wheel. This is a very precise process and has a huge significance in many operations.
Advantages of electrochemical grinding process-
1. Electrochemical grinding process provides excellent surface finish ranging from 0.05 micro meter to 1 micro meter.
2. Electrochemical grinding process provide better accuracy by selecting the wheel grinding size and abrasive particles accurately.
3. Electrochemical grinding process have very less tool wear when compared to many other processes related to material removal.
4. The main advantage of electrochemical grinding process is that there is no need of wheel dressing repeatedly. So it saves our time a lot.
5. In contrast to normal grinding process, electrochemical grinding process requires small amount of cutting force on the work piece.
6. There will be no surface cracks on the work piece or any wastage of work pieces.
7. The work piece material does not concern to any changes in its structure.
These are the advantages of electrochemical grinding process.
Disadvantages of electrochemical grinding process-
1. The rate of metal removal is very less and is about 15 Milli meter ^3 per second.
2. Initial cost of electrochemical grinding process equipment is very high.
3. Electrochemical grinding process requires more power for its operation.
4. Electrochemical grinding process can only process electrically non conducting materials but cannot process electrically conducting materials.
5. This process require frequent safety precautions in contrast to the corrosion by electrolyte.
6. The maintenance cost of electrochemical grinding equipment is very high.
7. The spare parts for electrochemical grinding equipment are not easily available in market.
Applications of electrochemical grinding process-
1. Electrochemical grinding process is widely used for grinding carbide cutting tools.
2. Electrochemical grinding process is specifically employed for grinding delicate components which involve thin walled structures, hypodermic needles and many more.
3. Electrochemical grinding can also be used for grinding hard, sticky and heat sensitive materials.
These are some of the applications of electrochemical grinding process.