Dr. B.R.

AMBEDKAR
NATIONAL INSTITUTE OF TECHNOLOGY, JALANDHAR
Advanced Manufacturing Processes
Tutorial Sheet 4

B.TECH 6th Semester

1. Calculate the material removal rate and the electrode feed rate in the
electrochemical machining of an iron surface that is 25mmx25mm in cross-section
using NaCl in water as electrolyte. The gap between the tool and the work piece is
0.25 mm. The supply voltage 12V DC. The specific resistance of the electrolyte is
3 Ω cm.
2. For example 1 estimate the electrolyte flow rate .specific heat of the electrolyte
is given as 0.997cal/g °C. The ambient temperature is 35 °C and electrolyte boiling
temperature is 95 °C.
3. Electrochemical machining is performed to remove material from an iron
surface of 20 mm x 20 mm under the following conditions:
Inter electrode gap = 0.2 mm Supply voltage (DC) = 12 V
Specific resistance of electrolyte = 2 Ω cm Atomic weight of Iron = 55.85
Valency of Iron = 2 Faraday's constant = 96540 Coulombs
Find the material removal rate (in g/s).
4. A researcher conducts electrochemical machining (ECM) on a binary alloy
(density 6000 kg/m3 ) of iron (atomic weight 56, valency 2) and metal P (atomic
weight 24, valency 4). Faraday's constant = 96500 coulomb/mole. Volumetric
material removal rate of the alloy is 50 mm3 /s at a current of 2000 A. Find the
percentage of the metal P in the alloy.