If can be difficult to find the best surface machining process for your production operations when your machining tolerances are very tight. We offer a solution that can fit many such manufacturing applications, our Precision Electrochemical Machining (PECM) process.
The PECM process works under the same principles of our ECM machines with the difference that a higher precision can be achieved.
In short, PECM offers all the benefits of our ECM process – accuracy, quality, consistency and repeatability – with the added advantage of higher overall precision for specialized applications.
Our PECM unit consists of four assemblies; Mechanical, Aqua, Control, and Power. The assemblies that make up the PECM unit work together to deliver high precision results to finished components.
How the PECM Process Works:
- PECM drives the cathode into the workpiece while maintaining a tiny gap (up to 10µm) throughout the complete cycle time. The oscillating motion is required to ensure the electrolyte flushing exchange.
- The DC pulse occurs only at the smallest gap.
- The quality of the cathode and the gap conditions are controlled to ensure desired results.
- Both oscillating and non-oscillating modes are available to ensure the highest productivity.
- Bipolar DC pulsing is incorporated into the process that cleans the cathode during and after the machining cycle to maintain constant operating conditions.
- A fully controlled process that includes an integrated quality control system.
- A precise machining control system that includes adjustment of the cathode movement and DC pulsing to allow the smallest gap sizes, highest repeatability, accuracy in the front gap, and a quality surface finish in the side gap.
- The operator interface provides a clear representation of the process stages which reduces the complexity of operation.
- Standardized power generators, electrolyte tank control, and regulated relevant electrolyte parameters work in unison to precisely control constant gap conditions.
- An ergonomic operation within an enclosed workspace that includes an automatic front door for worker protection along with a vented working area are used to maximize operator safety.
The PECM process delivers results that are difficult – if not impossible – to attain when using other machining methods.
Highlights of this process include:
Highest precision results. PECM provides the highest level of precision (+/- 5µm) for machining drilled holes or shaped surfaces.
Specialized application capabilities. Suitable for finishing components that are difficult to machine using other methods.
Streamlined production process. Shape, drill, and finish in a single pass with excellent surface finish results (Ra up to 0.03 µm). Since almost no post-processing of the workpiece is require, production time is reduced.
Enhanced component longevity. PECM does not create mechanical or thermal stress loads in the part. This means a longer life for end products.
Repeat accuracy. Achieves superior process control, stability and repeatability.
Increased productivity. PECM is a highly productive process. The process time is fast as compared to conventional methods and multiple parts per cycle can be machined resulting in a lower unit cost of production.
Economical. Drastically reduces production costs due to little or no tool wear.
Ease of Use. PECM machines are easy to automate and are easy to implement into a production line.