Electrosion Launches Compact ECM Machine

Electrochemical machining produces intricate shapes in very hard materials — fast.

by DE Editors | Published January 7, 2009

Close-up of bevel mold produced on the ECM 500.

Electrosion Ltd. (Mapplewell, Barnsley, UK) launched a new and compact ECM machine that brings very small electrode gaps, speed, and fuzzy logic to electrochemical machining. The ECM 500 uses Electrosion’s Impulse technology, which simultaneously pulses the power and the electrode so that extremely fine detail can be accurately reproduced in very hard materials such as tungsten carbide, making the machine suitable for use in the manufacture of cutting inserts, punches, and dies.

ECM differs from EDM in that the workpiece dissolves into the sodium nitrite electrolyte. The advantages of ECM are that metal removal rates are up to 100 times faster than EDM, electrode wear is virtually zero, making it unnecessary to manufacture multiple electrodes, and there is no stress or heat introduced into the workpiece.

With its Impulse pulsed flushing technology, the ECM 500 enables engineers to achieve electrode gaps down to 10 microns, which makes it possible to produce precise and intricate part geometry, while retaining the advantages of rapid metal removal.

Cavities and parts produced with the new machine will require little or no polishing with surface finishes of 0.1 Ra easily achievable.

New for the ECM 500 is its ability to machine tungsten carbide and titanium. The machine can erode tungsten carbide ten times faster than a laser, and produce a surface finishes of 0.2 Ra or better. For manufacturers, the technology will enable parts such as titanium femoral implants and tungsten carbide punches, dies and cutting inserts to be machined economically.

For details, contact Electrosion Ltd.

Sources: Press materials received from the company and additional information gleaned from the company's website.

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