Electrochemical Machining By BENSELER


The thermal deburring and electrochemical machining (ECM) deburring specialists at BENSELER can draw on over 40 years of expertise. ECM deburring is the automotive industry's first choice for defined rounding and surfaces in the edge area as well as components in the high-pressure range.

BENSELER offers you everything from a single source in the field of ECM: they rely on independence in the development of component-specific ECM technology and dimension, design and manufacture complex workpieces with different requirements completely independently.

Find out more about the advantages of Electrochemical Machining below.

What is Electrochemical Machining (ECM)?

The ECM deburring method is suitable for precise mold deburring and for rounding edges in precisely defined areas. Especially in hard-to-reach areas, such as internal bore intersections. To do this, the material is electrolytically dissolved on the anodically switched workpiece. This technique also allows contours to be worked into the workpiece surface. There are hardly any restrictions with regard to the alloy or microstructure of the components: BENSELER can deburr cast, pressed and forged parts and even hardened workpieces using this method.

Advantages of ECM Deburring at a glance

ECM deburring is a non-contact process: The workpieces are neither thermally nor mechanically stressed and no secondary burrs are formed. In contrast to conventional metalworking, there is no tool wear and no further polishing or deburring is necessary. Electrochemical machining enables very precise shape deburring and rounding of edges at precisely defined points - even in hard-to-reach areas such as internal bore intersections. The material properties remain virtually unchanged. This process can also be used to work contours into the workpiece surface.

Characteristics of ECM Deburring at a glance:

• Precise deburring at defined points
• Non-contact process
• Targeted deburring
• Suitable for processing thin-walled, sensitive workpieces
• Independent of workpiece structure and hardness
• No thermal or mechanical influence
• No formation of secondary burrs

Applications of ECM Deburring

Electrochemical Machining is mainly used in the automotive industry for medium and large series. However, other industries such as consumer, mechanical and plant engineering and medical technology also use ECM deburring. Metallic materials in particular are processed, as they are electrically conductive. Materials such as steel, stainless steel and aluminum are most frequently deburred using ECM.

ECM is particularly suitable for workpieces that require targeted material removal or a defined edge break on the inside and outside. The process is also ideal for components with complex internal geometries or shapes and for thin-walled and sensitive workpieces.

Examples of applications are:

• Defined roundings and edge breaks
• Shaping and countersinking: Creation of geometrically defined free forms:
   o Exposure of bore intersections
   o circumferential grooves
   o openings
   o Precise right-angled free forms
• Drilling using EC countersinks:
   o Generation of bore intersections to avoid difficult burr conditions and minimize tool wear
   o Application e.g. for materials that are difficult to machine
• Resetting of surfaces
   o Increasing the contact pressure on sealing surfaces
• Smoothing of surfaces
   o Improvement of running properties

For further information on our application examples, please contact us.

The Electrochemical Machining process sequence

ECM deburring: process diagram
ecm deburring process sheme

The processing points on the anodically switched workpiece are dissolved electrolytically with the aid of a tool cathode.

1. Preparation and development

The ECM process requires intensive coordination between BENSELER and the customer: The requirements for Electrochemical Machining are specified on the workpiece. Coordination should therefore take place at a very early stage, preferably during workpiece development.

2. Electrochemical Machining

With ECM, the workpiece to be processed (anode) is placed in a conductive liquid (electrolyte) during the process so that the electrical circuit between the workpiece and tool (cathode) is closed. When voltage is applied, an electric current flows across the working gap between the cathode and the workpiece. The resulting charge exchange processes transfer the material of the anode into the electrolyte solution in the form of ions. During the process, the workpieces are fixed in specially manufactured fixtures so that the machining point can be specifically controlled by the cathode. This is how BENSELER achieves optimum results. Other factors are the processing voltage and duration.

Our additional customer services for ECM Deburring

In addition to Electrochemical Machining, BENSELER offers the following customer services:

• Thermal deburring (TEM)
• Water jet deburring (HDW)
• Chemical deburring (CBE)
• Cryogenic deburring (KRE)
• Selective Laser Melting including finishing (SLM)
• Industrial parts cleaning

Other special services are available upon request.

These BENSELER locations offer this procedure:

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