The resulting synergetic effect is a 1+1=3 effect which implies that the combined effect of ECM with other process energy is more than double the benefits of individual process energies. The process has found various applications in MEMS, electronic, and aerospace industries, for its ability to produce high-aspect-ratio microholes, microstructures, microgrooves, etc. Multiple-groove, straight rifling was formed successfully in 7.62mm and 20mm, Cr-Mo-V steel (MIL-S-46047) gun barrel sections. Ribeiro, ... P.A.F. Active technical safeguarding such as an interlocking door system is important to avoid any electrolyte splash. Tool making for micro manufacturing applications opens news technological challenges by taking ECM a step forward to meet the precision requirements of complex geometric features in the micrometre range (Rajurkar et al., 1999). Further research and development on ECM process and on its derived and hybrid processes are continuing to meet various end product requirements. Most of the tools and equipment used to traditionally make a barrel are often cost-prohibitive and also require lots of training and experience to get done right. The electrolyte acts as a current carrier and must provide a high current efficiency η for the supplied current I to allow good material-removal rates (MRR): where C is a material constant and values of MRR typically range from 1 to 20 cm3/h depending on current density J. Electrolytes must also guarantee sensitivity between current efficiency and the supplied current in order to ensure high accuracy and quality of the ECM components (Chikamori and Ito, 1971). Several hybrid machining processes are resorting to ECM as one of the candidate process because of the following advantages of ECM: ECM has no tool wear and high surface finish as dissolution occurs at atomic level. The Setup in Freegunzone’s video is similar to many others with a cutting jig, electrical source and a 5-gallon bucket of saltwater being used to cut the rifling in the barrel without the need to specialized and expensive tools and equipment. Scaling down requires identification of the key operating parameters of ECM at the micro-level together with innovative solutions and concepts for the design and fabrication of machines for micro-ECM (μECM). Electrochemical machining (ECM) is also an environmental polluting process coming from the electrolyte and the ECM slurry. Tool making is among the manufacturing industries that have taken advantage of ECM for reducing or eliminating traditional finishing operations after hardening, namely the expensive hand-polishing of dies and moulds. Machining accuracy of the ECM process can be improved through maintaining very small interelectrode gap of the order of 20–50 μm during machining and by modulating the predominant process parameters. Settings. best. The process is used for various automotive and aircraft components, gun barrel rifling, steam turbine casings, and for deburring. Atanas Ivanov, ... Alexandre Spieser, in Micromanufacturing Engineering and Technology (Second Edition), 2015. Rifling a barrel is normally done by drilling the barrel stock, reaming it and rifling it using a series of tools – usually on a lathe. This is because the two process energies react with the workpiece and also interact with each other. Nguyen, in Comprehensive Materials Processing, 2014. Mathematical modeling of these processes based on the fundamentals involved is undoubtedly a challenging task, but is definitely required to improve the process control. If you google "electrochemical machining barrels ivan lbry tv" or similar I imagine you'd find it. It is a completely different process from electrochemical machining. 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