PEM PROCESS ADVANTAGES:

  • A high-precision shaping process, suitable for virtually any metal
  • Simultaneous machining of both macrostructures and microstructures
  • High standard of surface finish — close tolerance reproduction capability (2 - 5 µm)
  • Contact-free machining
  • Process doesn't cause any electrode wear
  • Metals can be machined regardless of material hardness
  • Surface finishes of Ra ±0.05µm or better achieved as standard (dependent on the process, material, and electrode selected).
  • Short processing times: feed rates between 0.1 and 3 mm/min
  • Suitable for all manufacturing volumes: mass production, batch quantities and prototyping
  • Absolutely burr-free
  • Virtually unlimited choice of conductive electrode material, dependent on the quantity of parts to be produced.
  • Consistent dimensional accuracy in series production
  • Process generates no thermal or mechanical stresses - producing NO change to material microstructure
  • A profitable and highly efficient process
  • No microcracks = excellent corrosion resistance achieved
  • No white layers
  • Components can be roughed, finished and polished in a single operation
  • Suitable for machining superalloys (inconel, hastelloy, etc.), powdered metal and titanium alloys

THE PROCESS

Precise Electrochemical Machining (PEM) is a powerful metal shaping process, ideal for simultaneously creating complex macro- and micro-structures in extremely hard or exotic materials which are difficult to machine with conventional methods — like superalloys (Inconel, Hastelloy), powdered metal, and titanium alloys.

A non-contact process, PEM uses electric current and an oscillating tool in a conductive electrolyte (salt water) to dissolve metal by liquefication. A positively charged workpiece (the anode) takes the form of the negatively charged tool (the cathode). The result is a burr-free part without thermal or mechanical stresses, microcracks, white layers or electrode wear.


Step-by-step: How does the PEM process work?

The PEM Process: Tool and workpiece are separated.  Fresh electrolyte flows. The gap is closed to within around 10 µm and a controlled pulse current is released. Tool and workpiece separate. The dirty electrolyte and eroded material are flushed from the gap. Cycle as needed; removing a small amount of metal each cycle to achieve burr-free parts.