EMAG CNC precision electrolytic machining application has great potential
June 21 02:15:11, 2025
Electrolytic processing is rapidly gaining popularity due to its distinct non-traditional cutting advantages, especially as technology continues to evolve. Thanks to advanced multi-axis linkage CNC precision electrolytic machining technology, EMAG Electrochemical in Germany has successfully implemented electrolytic machining for integral turbine blades and disc assemblies, effectively replacing high-speed milling and five-axis EDM.
Dorner, a pioneer in electrolysis technology across Europe, has been manufacturing high-quality electrolysis machines since 1990. By 2002, they had developed a precision vibration high-frequency narrow-pulse electrolysis machine along with its production processes. This marked the introduction of the world’s first multi-axis linkage CNC precision electrolysis machine. Following Dorner's integration into EMAG in 2009 and renaming to EMAG Electrochemical Machining Machine Co., Ltd., the company leveraged the CNC machining expertise of EMAG to significantly advance electrochemical processing technology.
EMAG combines its CNC machine tool manufacturing capabilities with multi-axis CNC precision electrolysis technology. Based on the principle of electrochemical anode dissolution, this method removes metal materials without applying cutting force, ensuring no wear on the cathode tool. It excels in processing intricate components like twisted titanium alloy blades at the end of compressors. Their five-axis EDM process allows for the complete electrolytic production of entire turbine blades and disc assemblies, surpassing traditional high-speed milling techniques.
As a leading innovator in electrochemical machining, EMAG Electrochemical Machining Machine Co., Ltd. boasts numerous patents in the field. They are recognized globally as the makers of the world’s first seven-axis CNC high-frequency narrow-pulse precision vibration electrolysis machine for aerospace engines, setting a benchmark for processing entire turbine disc assemblies. The electrolytic process ensures enhanced productivity and reduced costs. Additionally, their non-vibration electrolysis machines are extensively used in the production of high-pressure common rail injector needle bodies for diesel fuel injection systems.
EMAG’s non-vibration electrolysis machines and high-frequency narrow-pulse precision vibration electrolysis machines stand out as their key offerings. In Europe, they remain the sole provider of both types of electrolytic machinery.
One of the most impressive advancements from EMAG is their electrochemical deburring technology. Traditionally seen as a challenging task, deburring has been revolutionized by EMAG’s approach. By using an electrolytic process where the cathode tool feeds slowly over a stationary workpiece, only the burrs are removed while the core remains intact. A unique feature includes individual power supplies controlling multiple cathodes, allowing for independent processing of different parts. This setup ensures efficient protection of areas not needing deburring, minimizing cathode and energy wastage compared to competitors.
The precision and uniformity achieved through EMAG’s electrochemical machining ensure burr removal from complex components, even those made of extremely hard materials. Their patented computer-controlled process achieves machining accuracy up to Cmk 1.67 or higher. These machines are now widely used for deburring inaccessible sections of complex parts, such as intersecting ribs and cavities. EMAG continues to push boundaries in the field of electrolytic machining, offering solutions that combine efficiency, precision, and cost-effectiveness.
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