Applications of ECG are as follows;
(1) Single largest use for ECG is in manufacturing and remanufacturing of turbine blades and vanes for aircraft turbine engines
(2) Grinding of tungsten carbide tool inserts
(3) Re-profiling worn locomotive traction motor gears
(4) Burr-free sharpening of hypodermic needles
(5) Grinding of surgical needles, or thin wall tubes, and fragile parts
(6) Machining of fragile or very hard and tough material ? honey comb, thin walled tubes and skins
(7) High MRR?s when grinding hard, tough, stringy, work-hardenable or heat sensitive materials.

Desirable electrolyte properties are as follows-
? High electrical conductivity ? ease in ionisation
? Low viscosity – for easy flow
? High specific heat – to carry more heat
? Chemical stability – to be chemically neutral or does not disintegrate during reaction
? High resistance to formation of passivating film on workpiece surface
? Non corrosiveness and non-toxicity
? Inexpensiveness and easy availability.

In ECM, workpiece is used as an anode and cathode is made up of some conducting materials like aluminium, copper, brass, titanium, etc. In this process, product gets shape which is inverse as that of tool (cathode).

In order to obtain good results, it is essential to
i. remove contaminated electrolyte from working gap,
ii. minimize polarization,
iii. limit rise in temperature of electrolyte when working at higher current densities.

Generally simplest method of applying insulation is by spraying or dipping. Teflon, urethane, phenolic, epoxy, powder coating and or materials are commonly used for insulation. Sprayed or dipped coatings of epoxy resins are among most effective insulating materials. For optimum effectiveness, se coatings should be used with a protective lip on tool to protect edge of insulation from flow force of electrolyte.

Tool with an electrolyte supply slot is simple to manufacture, but such a slot leaves small ridges on work. However, ridges can be made very small by making slot sufficiently narrow. The flow from a slot takes place in a direction perpendicular to slot and flow at end is poor ? refore slot is terminated near corners of workpiece surface.

Increased pressure of electrolyte above atmospheric pressure increases boiling point of electrolyte point of electrolyte, reduces over-voltage required at tool surface and decreases volume of generated hydrogen due to which it displaces less electrolyte permitting use of higher current densities.

The accuracy of tool shape directly affects work piece accuracy, since configuration of cavity produced cannot be more accurate than tool produces it.

MRR= IA/(F?v)
MRR = 600 mm³/min = 600/60 mm³/s = 10 mm³/s = 10×10^-3cc/s
A= 56,
v= 2,
F= 96500 coulomb, and
? = 7.8 gm/cc
Therefore, I= (96500*10*10^-3*7.8*2)/56
I= 268.8A.

In practise, metal removal rates are often higher than estimated ones because;
(1) The exact valency at which a metal behaves in reaction is generally unknown.
(2) ECM continuously exposes a new and clean surface to electrolyte which is easily attacked chemically. It also varies with electrolyte used and metal being machined.