Abstract
Electro-Chemical Discharge Machining (ECDM) process has the potential to machine various features and 3D surfaces on glass. However, machining of high aspect ratio micro holes is a challenging problem in ECDM process. In ECDM process, the machining rate mainly depends on the availability of the electrolyte at the electrode tip. Machining accuracy like taper, entry and exit diameter of the hole at high depths is rigorously affected due to lack of electrolyte at the machining zone resulting in more taperness. Low surface qualities (i.e. more over cut and tapered micro holes) are few limitations of the process. To enhance the machining capabilities a novel approach of PMECDM has been conducted. Present study is mainly focused on behavior of abrasive particles while machining soda lime glass, also studied effect of process parameters on the responses such as machining depth, outer diameter and aspect ratio. Also, the study led to analyze the effect of thermal properties of abrasives on machining performance of ECDM process. The maximum machined depth achieved was 2.31 mm in 5 min, and tremendous reduction of outer diameter from 1237.37 μm to 712.8 μm. Response surface methodology has been used to plan the experiments and ANOVA has been used to analyze the impact of each process parameters on machined depth and outer diameter of the micro holes.
Highlights
In a state-of-the art of manufacturing technology, glass is the most widely used material in micro-electro mechanical devices (MEMS), due to its good bondage to silicon, and its similar coefficient of expansion
Adding abrasives into electrolyte does not promote the chemical etching, but it promotes the effects on the Electro-Chemical Discharge Machining (ECDM) mechanism in two aspects: First, the addition of abrasives maintains the gap which helps in the availability of electrolyte at the electrode tip as the machining proceeds
In the abrasive ECDM process, the machining gap is the order of same size of the abrasive particles
Summary
In a state-of-the art of manufacturing technology, glass is the most widely used material in micro-electro mechanical devices (MEMS), due to its good bondage to silicon, and its similar coefficient of expansion. Chow et al [10] conducted the EDM process by adding SiC and aluminum powders into kerosene for the micro slit machining of titanium alloy They reported that mixed SiC and aluminum powder to the kerosene enhanced the gap distance, resulting in higher debris removal rate and material removal depth. Balwinder singh et al [14] had mixed graphite, Al2O3 and SiC in ECDM process and reported that abrasive addition in electrolyte reduces the surface roughness. There is a need to improve the accuracy of micro hole machining like over cut quality and achieving maximum depth with less taperness in ECDM process. This paper deals with the effects of different process parameters like applied voltage (V), electrolyte concentration (wt%) on machined depth, entry diameter and aspect ratio during the drilling blind holes in soda lime glass. Response Surface Methodology has been used to plan the experiments and ANOVA (Analysis of Varience) has been used to analyze the responses
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