ECM-/PECM-Machines
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ECM-/PECM-Machines - 1

Machining / Drilling / Deburring

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ECM-/PECM-Machines - 2

EMAG ECM GmbH Complete solutions, development and ­ consulting. One contact for all your questions about electro-chemical machining.

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Electro-chemical machining

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++ Modular machine concept ++ Reliable supplier with high-level expertise in the development and manufacture of machine tools Electro-chemical machining is based on the principle of electrolysis. ++ More than 15 years of experience The tool, i.e. the cathode, is connected to a direct voltage source with the workpiece ­ acting as the anode. A charge exchange takes place between the cathode and the anode in an aqueous electrolyte solution which targets specific areas of the w ­ orkpiece. This can be used to create contours, ring ducts, grooves or bell hollows with no contact but very high...

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Tool Power source Workpiece Anode Functional principle »» Non-pulsed direct voltage »» Pulsed direct voltage Machining time per workpiece Machining time per workpiece Lower contour accuracy

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Electro-Chemical Machining – Maximum Precision and Economy Electro-chemical Machining (ECM) is the generic term used to describe various process variants. The ECM process manufactures workpieces through the electrolytic dissolution of metal. The process is used in the aerospace, automotive, medical, micro-system and energy industries. Almost all metals, even exotic materials such as nickel-based and titanium alloys or tempered m ­ aterials can be easily machined u ­ sing this process. The drawbacks of conventional m ­ etalworking, such as tool wear, m ­ echanical stress, micro-cracking from...

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The Advantages of Electro-Chemical Machining 1 Minimal tool wear (cathode), an ideal precondition ­ for batch production Very high repeat accuracy Peak-to-valley heights of up to Rz 0.2 / Ra 0.05 (depending on material) Highly efficient manufacturing process, no s ­ econdary operations such as deburring or ­polishing required Rough-machining, finish-machining and p ­ olishing in a single operation No thermal and mechanical effects, therefore, no changes in the material properties Machining materials which are difficult to cut Single blade »» Nickel-based alloys »» Nickel-based alloys »»...

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PECM PTS System The economical solution for machining demanding 2-D and 3-D geometries. »» Machine base made of MineraliT® polymer concrete »» Clamping surface: 800 x 550 x 515 mm (W x D x H) »» Machining area size 1,070 x 700 mm (W x D) »» Space requirement 2,100 x 3,200 x 2,900 mm (W x D x H) »» Oscillator with zero backlash »» Z-axis with max. 25 kN axial load »» Hydraulic zero point clamping system »» SIEMENS SINUMERIK 840D sl machine control unit »» Scalable generator technology with up to 12,000 A pulsed power »» Pulse duration from 50 µs to DC (direct current) »» Electrolyte...

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PECM PT System In addition to the PTS series, EMAG offers the PT series with the following advantages: »» Machine base made of MineraliT® polymer concrete »» Clamping surface: 800 x 450 x 660 mm (W x D x H) »» Machining area size 1,250 x 800 mm (W x D) »» Space requirement 1,500 x 2,200 x 3,500 mm (W x D x H) »» Oscillator with zero backlash »» Z-axis with max. 50 kN axial load »» Hydraulic zero point clamping system »» SIEMENS SINUMERIK 840D sl machine control unit »» Scalable generator technology with up to 20,000 A pulsed power »» Pulse duration from 50 µs to DC (direct current) »»...

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PECM PO 100 SF System The economical solution for the complex machining of turbine blades. »» Machine base made of Mineralit® polymer concrete »» Clamping surface: 370 x 450 x 360 mm (W x D x H) »» Machining area size 750 x 600 mm (W x D) »» Space requirement 2,800 x 2,300 x 2,600 mm (W x D x H) »» Oscillators with zero backlash »» X1- and X2-axes each with max. 25 kN axial force »» Y-axis »» Hydraulic zero point clamping system »» SIEMENS SINUMERIK 840D sl machine control unit »» Scalable generator technology with up to 24,000 A pulsed power »» Pulse duration from 50 µs to DC (direct...

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The uncompromising alternative to traditional machining of blade-integrated disks (blisks). » Machine base made of MiNERALiT® polymer concrete » Component diameter of up to 900 mm » Workpiece weight of up to 300 kg » Space requirement 4,400 x 6,600 x 4,500 mm (W x D x H) » Oscillators with zero backlash » X1- and X2-axes each with max. 50 kN axial force » Compound slide with adapter for blisk with Z-, Y-, B- and C-axes » Hydraulic zero point clamping system » SiEMENS SINUMERIK 840D sl machine control unit » Scalable generator technology with up to 30,000 A pulsed power » Pulse duration from...

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ECM CS / CI System The Comfort Standard and Comfort Integrated models are the p ­ erfect entry systems for automating the ECM process. »» Modular machine concept »» Intelligent software and hardware interfaces »» Manual or semi-automatic version starter systems »» Fast upgrade to full auto

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Siemens touch-screen panel Scalable generator technology Conductance monitor Temperature control pH value control with acid metering system Machining area 1,150 x 950 mm Quill stroke with safety interlock Two-handed control button operation Fast short-circuit shut-down

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++ Flow rates of up to 600 l/min ++ Electrolyte pressures of up to 20 bar ++ Temperature control ++ Flow rate and pressure monitor ++ pH value control by means of m ­ etered acid / alkaline addition ++ Particle size < 0.5 µm ++ Visualization and setting of all e ­ lectrolyte parameters on a S ­ IEMENS touchscreen panel Electrolyte Management System (EMS) For filtration, systems with chamber filter presses or with microfiltration are available. The filtrate quality and volume can thus be tailored precisely to your requirements. S ­ tandard systems from 40 to 600 l/min filtration capacity are...

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