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Procedia Technology 25 (2016) 1242 – 1249

Global Colloquium in Recent Advancement and Effectual Researches in Engineering, Science and
Technology (RAEREST 2016)

Experimental and Theoretical Investigations in ECDM Process –

An Overview
Lijo Paul a, Somashekhar S Hiremath b*
a
Dept of Mechanical Engineering, SJCET Pala, Kottyam, Kerala,686579, India
b
Dept of Mechanical Engineering, IIT Madras, Chennai 600036, India.

Abstract

The need for micro- machining of advanced engineering material started with increasing demand in aerospace, nuclear and
medical industries. Hybrid machining processes are introduced through the combination of the many non-conventional
machining processes thereby taking the advantage of more than one process. Electro Chemical Discharge Machining (ECDM) is
a novel hybrid machining process used for machining conducting and non-conducting engineering materials combining the
features of EDM and ECM processes. The present paper focuses on the theoretical study, design and development of
experimental setup, experimental investigation and control strategies in ECDM process, carried out so far by many researchers.

©
© 2016
2015TheTheAuthors.
Authors.Published
Publishedbyby
Elsevier Ltd.Ltd.
Elsevier This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of RAEREST 2016.
Peer-review under responsibility of the organizing committee of RAEREST 2016
Keywords: Non Conventional Machining; Hybrid Process; EDM; ECM; ECDM; ANFIS; Response Surface Methodology.

1. Introduction

Electro Chemical Discharge Machining (ECDM) is a newer and most potential non-conducting machining
process under the category of hybrid machining processes in which the material is removed through thermal energy-
melting followed by evaporation and chemical etching. This process combines the principles of Electro Discharge
Machining (EDM) and Electro Chemical Machining (ECM). The workpiece used for this process involves both

* Corresponding author. Tel.: 044 22574681; fax: +0-000-000-0000 .

E-mail address:somashekhar@iitm.ac.in

2212-0173 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of RAEREST 2016
doi:10.1016/j.protcy.2016.08.216
 Lijo Paul and Somashekhar S. Hiremath / Procedia Technology 25 (2016) 1242 – 1249 1243

conducting and non-conducting in nature. In ECDM, the discharge takes place between the tool electrode and the
auxiliary electrode of grossly different size immersed in an aqueous solution of electrolyte bath.

Nomenclature

EDM Electro Discharge Machining

ECM Electro Chemical Machining
ECDM Electro Chemical Discharge Machining Process
RSM Response Surface Methadology
FEM Finite Element Method
ECAM Electro Chemical Arc Machining
ANFIS Artificial Neuro Fuzzy Inference System
ANN Artificial Neural Network
EDM Electro Discharge Machining
FEM Finite Element Method
HAZ Heat Affected Zone
MRR Material Removal Rate
RSM Response Surface Modeling
ROC Radial Over-Cut
TWECSM Travelling Wire Electro Chemical Spark Machining
WECDM Wire Electro Chemical Discharge Machining

A critical appraisal of the research findings on the various domains of ECDM process is carried out in the present
paper. It includes brief history on the development, theoretical study, design and development of experimental setup,
experimental investigation and control strategies. A brief description of the major research findings are as follows.

2. Brief history

Crichton et al. [1] carried out a comparative study of EDM, ECM and Electro Chemical Arc Machining (ECAM)
processes. They have reported that EDM and ECM can machine only conducting materials while ECAM can
machine both conducting and non-conducting materials. McGeough et al. [2-3] conducted a theoretical and
experimental study of ECAM and reported that voltage and feed rates play a major role in Material Removal Rate
(MRR). They have reported a higher MRR at higher feed rate and higher voltage. Crichton and McGeough [4]
conducted experiments on ECAM with pulsed voltage circuit. Machining rate in terms of MRR was reported 5-40
times more than of ECM and EDM process and is represented in Fig. 1.They have observed four different stages of
electrical phenomena in the pulse circuit as (1) high frequency voltage and current oscillations, (2) high rate
electrochemical action, (3) low rate electrochemical action and (4) electro discharge action.

Tandon et al. [5] have machined Fibre Reinforced Plastic (FRP) composites with Electro Chemical Spark
Machining (ECSM) process. The experiments are conducted for an output response of maximum MRR, minimum
TWR, Relative Tool Wear Rate (RTWR), lower average overcut and top overcut. They have reported that MRR,
TWR increases with reduction in RTW with increase in voltage and conductivity of the electrolyte. Raghuram et al.
[6] have studied the influence of rectified DC voltage, smooth DC voltage and current on concentration of the
electrolyte in ECDM process. They have found that the external circuit parameter- inductance could give constant
power supply to ECDM process.

3. Experimental and theoretical investigations

Mechanism of spark generation during ECDM process was detailed by Basak and Ghosh [7-8]. They have
proposed a theoretical model for estimating the critical parameters -voltage and current in machining process.
1244 Lijo Paul and Somashekhar S. Hiremath / Procedia Technology 25 (2016) 1242 – 1249

Fig.1. Electrical Phenomena during ECAM with a Square Wave Pulse Input [4]
They have reported the discharge phenomenon is similar to a switching-off action of an electric circuit. Later they
introduced a simple ECDM model to predict the characteristics of the MRR with respect to voltage and inductance.
Ghosh [9] has further reported the spark generation is independent of the gas film breakdown at the tool electrode
and showed the inductance in the circuit as a parameter for improving the efficiency of the process. Gautam and Jain
[10] conducted experiments using various tool kinematics with a view to enhance the process capabilities. They have
reported that higher speed will disrupt the machined features and the depth of cut was increased with orbital rotation.
The MRR in ECDM process was also modeled and evaluated as a 3-D unsteady state heat conduction problem by
Jain et al. [11-12]. They have computed the temperature distribution with Finite Element Modeling (FEM) and
measured the material removal, spark generation, overcut and maximum penetration depth with developed model.
They have reported that abrasive cutting tools have shown an improved performance both in terms of material
removal and machined depth with an increase in supply voltage and temperature of the electrolyte. Jain and
Adhikary [13] carried out Electro Chemical Spark Machining with Reverse Polarity (ECSMWRP) as well as ECSM
with Direct Polarity (ECSMWDP). They have reported that reverse polarity increases the machining speed but at
the same time with very low surface finish. Yonghong et al. [14] have obtained high energy saving and efficiency in
machining of micro- hole in ceramic materials.

Bhattacharyya et al. [15] conducted the experiments using different electrolyte concentrations and voltage
combinations. It is observed that the tapered side wall and flat front tool tip shape is found to be the most effective
for producing circular holes. Somashekhar et al. [16] developed the electrochemical discharge machining setup for
profile cutting as shown in Fig.2. It was observed that the presence of tool vibration and side sparks affected the
profile produced on workpiece. Wuthrich and Fascio [17] conducted experiments with electrodes of grossly different
sizes in which anode has much larger size than that of the cathode.They have reported that beyond a certain value of
the applied potential, electrical spark appeared at the smaller electrode and the cell current dropped which they
called as electrochemical discharge phenomenon. Wuthrich et al. [18-20] also carried out experiments on SACE for
3D micro structuring of glass. They have obtained high aspect ratio and smooth surface quality for the machined
surfaces. They have reported that current-voltage characteristics of electrochemical cell are depended on the bubble
generation during machining process. They made a mathematical model for the evolution of bubbles evolved at the
working electrodes. Wuthrich and Hof [21] also attained repeatability in machining with SACE through reducing the
gas film thickness in ECDM process by increasing the wettability of the electrolyte.The electrochemical discharge
phenomenon from the current signal was studied to identify the gas film formations and the discharges in SACE
[22]. They have proposed an algorithm to measure experimentally the gas film life time and its necessary building
time prior to each series of discharges. Ziki and Wuthrich [23-25] reported that Stainless Steel (SS) tool have lower
tool wear due to higher thermal conductivity and thermal expansion.
 Lijo Paul and Somashekhar S. Hiremath / Procedia Technology 25 (2016) 1242 – 1249 1245

Fig.2. ECDM Cell

They have found that pulsed voltage could reduce the TWR and proposed that machining accuracy can be
obtained by adjusting the tool feed in proportional to TWR. They have further identified that surface heating affects
machining in low depths and flushing of electrolyte affects machining at higher depth. They have computed a
correlation between the forces applied at the tool tip with glass workpiece. They have utilized current signal as a
measure of contact between tool and workpiece. They later suggested force produced at the tool-substrate contact in
glass machining can be used as a source for monitoring the ECDM process. They characterized tool-glass contact in
drilling as chemical in nature, with good mechanical strength. They have reported that surface texture of the
machined surface can be improved by controlling the chemical bond occurring at tool- glass contact surface. Kim et
al. [26] have reported that HAZ produced on glass surface could be reduced using rectangular voltage pulses of
lower duty factors. Yang et al. [27-28] have reported that tungsten carbide produced smallest hole diameter with
least tool wear. They have revealed that the gas bubbles of bigger mean diameter are formed on tool electrode of
greater surface roughness. They also studied the tool geometry effect with a spherical end tool electrode (diameter
150 μm) and cylindrical tool electrode (diameter 100 μm). The results showed that machining time was reduced by
83% while hole diameter was decreased by 65% with spherical end tool electrode as shown in Fig.3.

Fig.3. Cutting tools with cylindrical and spherical shapes [28]

Sarkar et al. [29-30] have found that the voltage has higher influence on MRR with lower ROC and Heat Affected
Zone (HAZ). They have used Analysis of Variance (ANOVA) table in order to study the parameter interaction and
carried out the confirmation test for the same. Chak and Rao [31-32] have reported that abrasive rotary tool
increased the machinability and MRR due to abrasive particles present in machining. They have revealed that the
abrasive rotary electrode was better than the hollow stationary electrode for better MRR. The MRR was predicted
using ANFIS. Han et al. [33-34] have reported reduction in breakdown voltage and 10 % reduction in peak current
during machining of borosilicate glass with the addition of graphite powder in the electrolyte. They have found that
the conducting powder stabilizes the discharge current in ECDM process as discharge energy dispersion takes place
through the conducting powder mixed in the electrolyte. Later they have conducted experiment with side insulated
tool and reported that uniform gas film formation would give better geometry in micro-machining. West and Jadhav
[35] machined micro-holes with repeatability on borosilicate glass with electrolyte concentration and temperature of
electrolyte as process parameters. They have reported that the spherical shaped microstructure is produced with
anodic process at lower electrolyte concentration and higher temperature of the electrolyte. Zheng et al. [36-37]
conducted micro drilling of glass wafers with flat sidewall–flat front tool and pulse DC voltage. They have reported
1246 Lijo Paul and Somashekhar S. Hiremath / Procedia Technology 25 (2016) 1242 – 1249

reduction in HAZ, overcut and taper hole during drilling operation. They found that the quality of microfeatures
could be improved with decrease in voltage and mean machining time.

Furutani and Maeda [38] have conducted experiments with tool rotation and reported that depth, width and
surface roughness of the groove increased with increase in applied voltage. They have reported that width of the
groove decreased with rotation due to tool vaporization in ECDM process. Coteata et al. [39-40] carried out
experimental study on the influence of the electrode tool diameter, voltage, capacitance of the electric circuit and
density of the electrolyte on the axial tool wear during machining. Liu et al. [41] has studied the discharge
mechanism in composite material and modeled the effect of electric field on hydrogen bubble formation. The model
predicted the position of the maximum field strength on the bubble surface as well as the critical breakdown voltage
for spark initiation, for a given processing condition. Tang and Zhao [42] found that ultrasonic vibration; abrasive
particles in electrolyte and side-insulated electrode improve MRR of pyrex glass. Razfar et al. [43] conducted
experiments with cylindrical rod and micro drill tool materials. They reported that cylindrical tool with square wave
pulse show improvement in MRR than sinusoidal pulse waves. Huang et al. [44] machined micro-holes on stainless
steel workpiece with ECDM process at high speed tool rotation with pure water as electrolyte. They have reported
that voltage has significant influence on the TWR followed by the tool rotating speed and the diameter of tool
electrode. Chavoshi and Behagh [45] determined the effective process parameters range for electrode-tool diameter,
capacitance, work liquid density and voltage through mean analysis, main effect plot and Pareto ANOVA methods
which affected the depth of the hole. Lijo and Somashekhar [46-47] had conducted Response Surface Modeling
(RSM) of ECDM with pulsating DC to understand the effect of various process parameters on micro hole and micro
channel machining for MRR, TWR, HAZ and Radius of Overcut (ROC) as shown in Fig.4 (a) and Fig. 4(b). MRR
decreases at higher depth due to lower spark which was due to unavailability of electrolyte . Lijo and
Somashekhar [48-49] have also carried out multi objective optimization with grey relational analysis. They have
reported that heat affected zone can be reduced with low duty factor during machining. Lijo et al. [50] also reported
that higher frequency at low duty factor will increase MRR with reduction in HAZ. Ranganayakulu et al. [51] used
ANFIS for modeling of ECDM and found that voltage had predominant effect on MRR than electrolyte
concentration and tool feed rate. Micro-ECDM was studied by Cao et al. [52] in order to improve the machining of
3D micro-structures of glass as shown in Fig.4(c). In this study, various microstructures less than 100 µm in size,
such as 60 µm diameter micro-holes, a 10µm thin wall and a 3D microstructure were fabricated to demonstrate the
potential for micro-machining of glass by ECDM.

(a) (b) (c)

Fig.4. ECDM setup based on constant velocity tool feed systems [52]
4. Modeling and control strategies

Fascio et al. [53-55] found that repeatability with accuracy was impossible at higher depth due to lack of tool tip
geometry control. They have also investigated machining of glass using current/voltage measurements. They have
reported photographs of the tool electrode under different regimes. Due to the ohmic heating, the temperature near
the tool electrode reaches the boiling point of the electrolyte resulting in the generation of water vapour bubbles.
These bubbles cover the active surface area of the tool electrode, leading to blanketing. Once the bubbles dislodge
from the tool surface, contact between the electrolyte, tool is re-established, and the cycle will be repeated. They
 Lijo Paul and Somashekhar S. Hiremath / Procedia Technology 25 (2016) 1242 – 1249 1247

later proposed two theoretical models of SACE process. First model is based on percolation theory and they
predicted the critical parameters - voltage and current in spark generation. Second model is to estimate the spark’s
characteristics- amplitude and duration. Mediliyegedara et al. [56-57] simulated the pulse voltage used in ECDM
process with Artificial Neural Network (ANN). They have showed that ANN can be used as a pulse classification
tool in ECDM process for various industrial applications. A system identification experiment was carried out to
obtain the dynamics of the system and a process control algorithm was implemented in software form. Later they
designed and developed an Intelligent Process Controller (IPC) for the ECDM process. They demonstrated the
application of ANFIS for generating control signals for monitoring the machining gap. Kulkarni et al. [58-59]
attempted to identify the underlying mechanism of ECDM through experimental observations by time-varying
current in the circuit. They have also designed and developed a 5-degree freedom ECDM machine with 3-degree
freedom for three axis motions. They have reported that the melting of engineering material in the machining zone
was due to bombardment of electrons, generated due to spark at temperatures of 3000 0C.

Skrabalak et al. [60] developed a simplified model for the estimation of current in electrochemical dissolution and
electro discharge in the ECDM process. Bhondwe et al. [61] developed a thermal model for the prediction of MRR
during ECSM. The developed finite element based thermal model, was found to be in the range of accuracy with the
experimental results. Nandi et al. [62] have reported that there were three distinct regions in the V-I characteristics
for alkaline, neutral and acidic electrolyte. The span of the curve region near to the spark is different for various
electrolytes and they concluded that local turbulence has little effect on critical voltage or critical current. Wei et al.
[63-64] tried to model ECDM process in discharge regime (less than 300 µm depth) with a single spark using FEM.
They calculated the fraction of power transferred to workpiece as 29% in discharge regime. They also carried out a
novel application of ECDM with micro-tool grinding process. Manna and Narang [65] had performed multiple linear
regression mathematical models on machined hole for MRR and ROC. They reported close similarity of machining
performance with mathematical models. Krotz et al. [66] has modeled single spark in ECDM process with
COMSOL. They simulated the diameter of the HAZ and found that it was independent of the discharge time and
heat transfer rate due to heat flux. Jiang et al. [67] proposed a FEM to correlate the spark energy and the geometry of
material removed in ECDM process. MRR is treated as heat transfer problem as electrical energy released by spark
generation is transferred as thermal energy to the workpiece. Predictions of material removal by the model
demonstrated good consistency with experimental results.

5. Conclusions

x From the detailed review of literature, it has been noticed that the ECDM process is a potential and
emerging non-conventional machining process to machine various non-conducting engineering materials
to the required precision and accuracy without any difficulty.
x Experimental setups are developed in various stages and contains cathode (tool), auxiliary electrode,
workpiece immersed in aqueous solution of NaOH, KOH etc.
x Researchers have carried out experiments with different tool geometries to study MRR, HAZ and TWR.
x Many have tried modeling aspects and simulation aspects – FEM/ANN to study the characteristics of
ECDM process.
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