| Aspect | Electrochemical Machining (ECM) | Electrical Discharge Machining (EDM) |
|---|---|---|
| Process | Uses electrolyte and controlled electrical current to dissolve metal | Uses electrical discharges (sparks) to erode metal |
| Material Compatibility | Conductive materials, including complex shapes and hardened alloys | Conductive materials, but limited to simpler geometries |
| Accuracy | Very high precision | High precision |
| Surface Finish | Excellent surface finish | Good surface finish |
| Complexity | Capable of complex geometries | Limited to simpler shapes |
| Material Removal Rate | Low material removal rate | Higher material removal rate |
| Tool Wear | Minimal tool wear | Moderate tool wear |
| Heat Generation | Minimal heat generation | Generates heat |
| Applications | Aerospace, medical devices, intricate components | Tool and die making, mold manufacturing |
| Environmental Impact | Generally low (no thermal or mechanical stresses) | Minimal thermal and mechanical stresses |
| Cost | Higher operational costs | Lower operational costs |
Conclusion:
Electrochemical Machining (ECM) offers very high precision with excellent surface finish, making it suitable for intricate parts and complex geometries. However, it operates at a lower material removal rate compared to Electrical Discharge Machining (EDM), which is more suitable for rapid material removal in simpler shapes. Each method has its niche based on the requirements of precision, material type, and desired production rates.