AUTOMATION OF

ELECTROCHEMICAL ETCHING OF
FERROUS AND NON-FERROUS
A CTDT PROJECT
MATERIALS

Guided by
Prof.A.JOTHILINGAM
Dr.P.GANESH
(2010507034)
DEPARTMENT OF PRODUCTION TECHNOLOGY
(2010507027)
MIT CAMPUS
ANNA UNIVERSITY - CHENNAI

Project members
S.Naveen (2010507034)
S.Parthiban
K.Mathan Kumar

ELECTROCHEMICAL ETCHING
Electroetchingis a micro-level metalremovingprocessthat
involves the use of a solution of anelectrolyte, ananodeand
acathode.
The metal piece to be etched is connected to the positive
pole of a source ofdirect electric current.
A piece of the same/different metal is connected to the
negative pole of the direct current source and is called the
cathode.
Etching is made possible by the combination of both
chemical and electrical means.

MATERIAL REMOVAL - PRINCIPLE

Some compound when dissolved in a solvent splits into
positive and negative ions and they are termed as
Electrolyte
The electrolyte do the chemical part of the process.
When DC potential is applied, the anode is oxidized and
gets dissolved into the electrolyte.
Generally electrolyte contains two type of ions, one is
similar to the cathode in case of deposition of metal
over cathode is desired and the other ion is to regulate
the current flow in the circuit.

PARAMETERS
Current Density
Interelectrode gap
Electrolyte type
Electrolyte concentration
Power supply
Voltage
Electrolytic flow

SETUP PLAN
A plain cylindrical roller is used as cathode and it hangs below.
The roller hangs on with the help of vertical setup supported by two
sliders.
The vertical setup is attached to the leadscrew which inturn is coupled to
a DC stepper motor.
A flat sheet of metal is the work piece and is made anode. A template
with desired pattern is placed over the workpiece.
The roller rolls over the workpiece providing contact between
itself(cathode) and the workpiece(anode)
The electrolyte is poured over the workpiece.
As the leadscrew rotates the roller moves traversely over the workpiece.

AUTOMATION
Automation is mainly concentrated on the motor. By
controlling the motor polarity the direction of the tool
travel is determined.
MATLab software is used to control the motor activities.
Two sensors are attached at both the ends of the setup.
When the roller travels the desired length the metal
sensor detects it and the motor polarity is reversed.
Depend upon the type of workpiece used the time of
tool travel over the workpiece is altered with the help of
MATLab.

PROCESS CAPABILITIES
Work piece of thickness upto 1cm can be etched.
Any flat workpieces within the standard dimension of 300
300 mm can be etched.
All the metals of any type can be etched i.e., both the ferrous
and non ferrous, provided nominal electrolytic composition.
Potassium chloride : 80 gms
Sodium chloride : 90 gms
Nitric acid : 100ml
Hydrochloric acid : 100ml
Water : 4.5litre

The tool completes one complete stroke in 9.21 mins.

WHAT? WHY?
Base plate
Roller
Motor
Lead screw
Template
Power supply source
Work piece

APPLICATION

For the purpose of drawing standard circles on the

metal sheet to measure the strain on the work piece
used in the formability measuring experiment.

ADVANTAGES
No heat affected zones as in case of laser etching
Stress free process unlike in a stamped workpiece
Heating of the work piece is almost averted during the
process.
Since small amount of material is removed, weight loss
of the component is negligible.
Less material removal means less metal dissolution
which is easy to dispose of.
The etch rate is uniform all over the surface provided
the surface is exactly flat.

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THANK U