EMAG CNC precision electrolytic machining application has great potential
June 21 02:33:06, 2025
Electrolytic processing is gaining significant attention due to its unique advantages in non-traditional cutting techniques, particularly with the rapid advancement of technology. Leveraging multi-axis linkage CNC precision electrolytic machining technology, EMAG Electrochemical Company in Germany has made impressive strides in the industry. They’ve successfully implemented electrolytic machining to produce entire turbine blades and blade discs, effectively replacing traditional high-speed milling and five-axis EDM methods.
Dorner, a pioneer in electrolysis technology in Europe, has been a major player since its inception in 1990, focusing on high-quality electrolysis machinery. In 2002, they introduced a precision vibration high-frequency narrow-pulse electrolysis machine and its production process, marking a breakthrough with the world's first multi-axis linkage CNC precision electrolysis machine. Following Dorner’s integration into EMAG in 2009 and its subsequent rebranding as EMAG Electrochemical Machining Machine Co., Ltd., the collaboration with EMAG's CNC machining expertise accelerated advancements in electrochemical processing.
EMAG utilizes its CNC machine tool platform to enhance multi-axis CNC precision electrolysis machines. By combining multi-axis CNC linkage capabilities with precise electrolytic machining principles—where metal is removed through electrochemical anode dissolution—the process eliminates cutting forces, ensuring no wear on the cathode tool. This makes it ideal for machining intricate components like titanium alloy blades and end-stage compressor alloys. Their five-axis EDM process allows for the complete electrolytic production of turbine blades, eliminating the need for high-speed milling.
As a leading innovator in electrochemical machining, EMAG Electrochemical Machining Machine Co., Ltd. holds numerous patents in this field. They've pioneered the world’s first seven-axis CNC high-frequency narrow-pulse precision vibration electrolysis machine for aerospace engines, making them the sole European equipment provider for machining entire turbine blade discs. The entire process is electrolytic, boosting productivity while significantly reducing costs. Additionally, their non-vibration electrolysis machines (using DC or pulse power) are extensively used in the production of high-pressure common rail injector needle bodies for diesel fuel injection systems in Europe.
These two electrolysis machines—non-vibration electrolysis machines and high-frequency narrow-pulse precision vibration electrolysis machines—are standout products of EMAG Electrochemical Machining Machine Co., Ltd. In Europe, EMAG remains the sole manufacturer offering both types of electrolytic machines.
A notable achievement in EMAG's portfolio is their success in electrochemical deburring technology. Traditionally seen as a troublesome process, EMAG has transformed deburring into a streamlined and efficient operation. The unique feature of their electrochemical deburring machine lies in its low-speed cathode tool feed, which performs electrical discharge machining on stationary workpieces. This approach ensures precise electrolysis of burrs without affecting the core structure. A single power supply controls individual cathode tubes, allowing independent processing of each part, while the closed cathode runner design protects areas not needing deburring. This ensures optimal machining accuracy with minimal cathode and energy loss, just a fraction of competitors' consumption.
EMAG’s electrochemical machining technology excels in deburring complex workpieces, even those with extreme hardness or toughness. Their patented 100% computer-controlled process achieves machining accuracy at Cmk 1.67 or higher. Today, these machines are widely applied in deburring hard-to-reach sections of complex shapes, such as intersecting ribs, cavities, and cross-sections.
In summary, EMAG’s innovations in electrolytic machining have revolutionized various industries, offering efficient, cost-effective solutions with unparalleled precision and versatility.
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