5 - Microelectrochemical machining: Principle and capabilities

Abstract

Electrochemical machining (ECM) has been widely used in manufacturing owing to its capability of machining hard metals in the absence of mechanical stress, heat-affected zone, and tool wear. Allowance in microelectrochemical (micro-ECM) machining can be removed in electrochemical drilling, milling, or cutting through a relative movement between a workpiece and a universal electrode tool. The purpose of this chapter is to review the state-of-the-art development and capabilities of micro-ECM technology. Some key fundamentals of microelectrochemical machining, e.g., principle, utilization of ultra-short pulses, and miniaturization of cathode, have been briefly introduced in Section One. Section Two demonstrates a variety of micro-ECM approaches, which involve micro-ECM drilling, micro- ECM milling, through-mask micro-ECM, microwire electrochemical cutting, and electrochemical jet machining. Section Three presents several hybrid machining processes combined with micro-ECM, which have been the research interest over the last decade.