Electrochemical Discharge Machining Research Articles

Investigation of the influence of different types of electrolytes on the performance of the Electrochemical Discharge Machining process during micromachining of molybdenum

Electrochemical Discharge Machining (ECDM) is a hybrid process that integrates the principles of Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM) to create micro-holes in both conductive and non-conductive materials that are typically difficult to machine. Given the unpredictable nature of this hybrid method, the composition of the electrolyte emerges as a critical factor influencing the accuracy and performance of the machining process. Consequently, the optimization and analysis of electrolytes are pivotal for the efficient utilization of energy during ECDM and for ensuring machining precision. This study aims to experimentally investigate the impact of various types of electrolytes and their concentrations. These are divided into two categories: neutral solutions, which include sodium nitrate (NaNO₃) and sodium chloride (NaCl), and alkaline solutions, comprising sodium hydroxide (NaOH) and potassium hydroxide (KOH), as well as a mixture of both NaOH and KOH. The evaluation metrics considered include the Material Removal Rate (MRR), Tool Wear Rate (TWR), overcut (OC), Heat Affected Zone (HAZ) and surface quality. It was observed that alkaline solutions, particularly the mixed electrolyte, resulted in higher MRR and HAZ, reduced TWR, and the production of micro-holes with minimized overcut compared to using KOH and NaOH separately or neutral solutions, while also enhancing surface quality. Further analysis using Scanning Electron Microscopy (SEM) images and Energy-Dispersive Spectroscopy (EDS) of the brass tools used with different electrolytes revealed that tools used in KOH and mixed electrolytes exhibited less wear and material erosion compared to those used in NaOH and neutral solutions.

Issues of gas film stability with performance characteristics in u-ECDM: A review of existing approaches and preliminary investigation on proposed stable & sustainable approach

Micro-featured devices (made of glass and its composites) are becoming increasingly necessary for Micro Electro-Mechanical Systems (MEMS) and healthcare devices with the emergence of technology. Due to limitations of existing methods, Micro Electro Chemical Discharge Machining (μ-ECDM) is an evolving technique for difficult to micro machine materials like glass. However, improper flushing and unstable electrolytic conditions in the processing zone percolates the efficacy, accuracy, and repeatability of μ-ECDM. Consequently, deteriorating the sustainability and industrial feasibility of this process. To cope up with these problems, various approaches like ultrasonic assistance, rotary mode, magneto hydrodynamic are integrated and investigated with μ-ECDM in the literature. Although these approaches achieved the intended objectives but do not assure the stability and sustainability of the process, which are essential for industrial feasibility in the present scenario. The present review has stressed upon the effects of existing approaches on gas film formation, discharge characteristics and performance outcomes. Systematic review methodology indicated the extensive usage of ultrasonic vibrations in μ-ECDM and, the studies on the stability/sustainability of μ-ECDM process are neglected. According to literature and preliminary investigation, problems pertaining to the rising electrolyte temperature and heterogeneous electrolyte concentration are the attributed reasons, which affects the stability as well as sustainability. Therefore, the present review proposed an innovative approach to achieve the stability and sustainability of μ-ECDM process by controlling the electrolytic conditions (termed as controlled-ECDM). A preliminary experimental investigation witnessed the enhancement of process performance and quality characteristics in controlled-ECDM.

Optimization of micro-ECDM performances during micro-channeling on glass using Taguchi technique

The present research work is aimed toward optimize the micro-ECDM (Electro Chemical Discharge Machining) parameters like applied voltage, electrolyte concentration, duty ratio and pulse frequency on the optimum micro-channeling performances on borosilicate glass. Micro-ECDM tests were performed on borosilicate glass in well-established ECDM set-up under different applied voltage, electrolyte concentrations, duty ratios and pulse frequencies. Several micro-ECDM performances on glass like material removal rate (MRR), surface roughness (SR) and width of cut (WOC) were investigated for every matching test condition. The signal noise (S/N) ratio and best fitted ANOVA analysis as-well-as predicted results, mean and standard deviation has been propounded during micro-channel machining process. Heat affected zone, radial overcut and morphology of debris were investigated under scanning electron microscope. The micro-ECDM parameters have been optimized by applying Taguchi Technique on the experimental results and observations. The optimum micro-channeling performances during micro-ECDM process on glass are observed at applied voltage of 50 V, 25 wt% electrolyte concentration, 0.5 duty ratio and 50 Hz pulse frequency.

Etching of quartz crystals in liquid phase environment: A review

Quartz crystals are the most widely used material in resonant sensors, owing to their excellent piezoelectric and mechanical properties. With the development of portable and wearable devices, higher processing efficiency and geometrical precision are required. Wet etching has been proven to be the most efficient etching method for large-scale production of quartz devices, and many wet etching approaches have been developed over the years. However, until now, there has been no systematic review of quartz crystal etching in liquid phase environments. Therefore, this article provides a comprehensive review of the development of wet etching processes and the achievements of the latest research in this field, covering conventional wet etching, additive etching, laser-induced backside wet etching, electrochemical etching, and electrochemical discharge machining. For each technique, a brief overview of its characteristics is provided, associated problems are described, and possible solutions are discussed. This review should provide an essential reference and guidance for the future development of processing strategies for the manufacture of quartz crystal devices.

Experimental investigation of micro-machining of borosilicate glass using an ultrasonic assisted rotary electrochemical discharge machining (UA-RECDM) process

Electrochemical discharge machining is an advanced micro-machining process for machining of conductive as well as non-conductive hard and brittle materials, e.g. glass, ceramics, silicon wafer, etc. The present work explores the machining of glass using an in-house developed novel ultrasonic assisted rotary electrochemical discharge machining setup. The setup has specialized features, such as using ultrasonic vibrations to tool the electrode and incorporating rotary motion for manipulating the workpiece. Experiments were conducted using a one factor at a time approach by varying the tool feed rate, the amplitude of the vibrations and the rotation of the workpiece as process parameters. The quality of the machining output was evaluated by observing two key parameters: the overcut and the circularity of the hole. It was observed that as the workpiece rotation speed increased from 40 rpm to 60 rpm, the overcut in the machined samples decreased from 181.378 μm to 163.564 μm. The rotary motion of the workpiece caused a seeping action of the electrolyte in the hydrodynamic regime, leading to the formation of a thin gas film and the stabilization of the discharging process. The morphology of the machined hole exhibits better circularity, low heat-affected zones, minimum micro-cracks and smooth edges at its periphery due to stable discharge formation.

Experimental and numerical investigations into the fabrication of alumina ceramic surface microchannel by electrochemical discharge machining

The electrochemical discharge machining (ECDM) is an advanced and promising technology for fabricating micro structures. This method is effectively applicable for non-conductive hard and brittle materials micromachining, such as glass and ceramics. However, the ceramics high melting point and intense heat exchange effects during microchannel fabrication lead to the easy dissipation of thermal energy and the difficulty in processing. To address this issue and expanded the ECDM processing range. This paper dedicated to the investigation of the material removal mechanism and process characteristics for the alumina ceramic surfaces microchannels preparation. Firstly, this study explained the difference of the ECDM critical applied voltage and gas film generation mechanism by analyzing the volt-ampere characteristic curve of 20 wt% NaOH electrolyte with a tool immersed depth of 2 mm and 10 mm respectively. Then, a thermal removal finite element model (FEM) for ECDM was developed. The heat cumulative and intermittent cooling effects applied on the alumina ceramic surface dominated the materiel removal. Additionally, it can be found that the microchannel machining accuracy and bottom surface quality depended on the Gaussian heat source characteristics, gas film formation mechanism, heat accumulation effect, and temperatures spatial and temporal distribution. And a series of single factor experiments for evaluating the parametric studies such as the effect of discharge frequency, applied voltage, duty ratio and tool feed rate on the fabricated microchannel performance are executed. Finally, the complex three-dimensional structures of cross microchannel grid and zigzag microchannel array with variable depth were successfully fabricated on aluminum oxide ceramic surface. Notably, the results highlighted and enriched the ECDM stability, consistency and applicability for alumina ceramic surface microchannel fabrication.

Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature

Glass vias are emerging as a favourable option for radiofrequency-based micro-electromechanical system packaging. For the micromachining of glass, electrochemical discharge machining (ECDM) could be the most suitable technique if issues pertaining to the process stability are addressed thoroughly. The electrolyte temperature has immense influence on the viscosity and conductivity of the electrolyte, which percolate the stability of the ECDM process. Therefore, this article investigates the effects of the electrolyte temperature and applied voltage on the performance characteristics of ECDM for the micromachining of borosilicate glass. The machining rate (MR) and hole overcut (HOC) of the machined microholes are considered as performance characteristics. A 3D thermal-based finite element model (FEM) was developed for the thermal analysis in the machining zone. In the thermal analysis, the heat flux by thermal discharge was assumed to have Gaussian distribution, and accordingly, temperature profiles in the thermal zone were analyzed by controlling the electrolyte temperature and voltage at various levels. Further processing of temperature profiles in the thermal zone was utilized in the estimation of MR and HOC. Electrostatic-based FEM was utilized to assess the intensity of the electric field in the proximity of the tool electrode to analyze the probable locations of thermal discharge and its impact on the geometrical characteristics of the machined microholes. The simulation outcomes were validated experimentally, and show good agreement. A field emission electron microscope with energy dispersive spectroscopy was used for the characterization of the machined surface to observe the effect of the electrolyte temperature.

Application of Multi-Criteria Decision Model to Develop an Optimized Geometric Characteristic in Electrochemical Discharge Machining

Application of Multi-Criteria Decision Model to Develop an Optimized Geometric Characteristic in Electrochemical Discharge Machining

Sinking ECDM micro-milling of micro-channels with a customized electrode

ABSTRACT Electrochemical discharge machining (ECDM) micro-milling exhibits enormous machining potential in manufacturing metal microstructures. In this paper, a novel sinking ECDM micro-milling using glycol-based electrolyte is proposed for the high-quality fabrication of metal micro-channel structures. Firstly, a novel combined process is developed for the simple and efficient preparation of micro-electrode. With the proposed method, a micro-electrode with 91.1 μm in diameter and 21.2:1 in aspect ratio is successfully machined in 47.2 minutes. Secondly, experimental research on ECDM micro-milling machining of micro-channels in glycol-based electrolyte is carried out using the fabricated micro-electrode. Experimental results show that the machined voltage significantly affects the machining quality of micro-channels. Wear analysis reveals that the bottom geometry of the micro-electrode exhibits equal wear along the axis direction with processing times increasing, and a constant length compensation strategy (1.52 μm/mm) is adopted. Finally, an S-shaped micro-channel without recast layers (Ra 0.093 μm) was successfully fabricated.

Characteristics and improvement of the double-pass electro-chemical discharge machining

Glass and ceramics have broad applications in modern industries; however, unique properties such as brittleness, and low machinability limit their fabrication processes. This way, electro-chemical discharge machining (ECDM) is a new method that can shape hard, brittle, and non-conductive materials. ECDM improvement is the subject of recent investigations through the application of chemical and physical phenomena. Current research studies the accuracy and surface integrity (cracks and HAZ) aspects of the double-pass ECDM process (DP) which is a new and straightforward method. During the double-pass process, two sequential passes are employed to shape the final geometry. In addition, the variable voltage technique is studied to achieve higher machining efficiency in DP. Results showed that in the diameter difference of 100 µm, the double-pass process reduced overcut by up to 21% compared to the typical ECDM process. Also, the size and number of cracks and the extent of HAZ were significantly decreased. Finally, in the diameter difference larger than 300 μm (the constant voltage of 32 V), the enhancement modification (variable voltage) reduced the overcut by more than 80%. At the same time, depth results remained close (less than 5% difference) to the simple ECDM process.

Micro ECDM process comparison using different tool feed methods of constant gravity and spring-force

Quartz glass has been widely used in multiple frontier fields of science and technology owing to its excellent chemical and mechanical properties, such as optical communication, semiconductor, photovoltaic power, and aerospace. ECDM (electrochemical discharge machining) is a non-traditional material removal process suitable for machining non-conductive materials of high hardness and brittleness. The tool electrode feed method is a key factor affecting the ECDM process. Experimental research was carried out for comparing the conventional gravity feed method and a newly-developed spring-force feed method. Micro tool electrodes of Φ150 µm were fabricated by combining the method of TF-WEDG (tangential feed-wire electrical discharge grinding) and reverse micro EDM (electrical discharge machining). Machined microstructures of blind holes, channels, squares, and patterns were compared by the gravity feed method and the spring-force feed method respectively. The experimental results show that the spring-force feed method can improve the micro ECDM process considering the aspects of dimensional accuracy, overcuts, deteriorated edges, surface topography, and tool wear.

Micro-ECDM Performances Analysis Using Fuzzy Logic and ANFIS During Micro-Channel Fabrication on Silica Glass

Higher accuracy and meticulousness are highly demandable in modern industrial field during micro-machining performances by electrochemical discharge machining (ECDM) process. The paper deals with the experimental fuzzy logic control (FLC) analysis as well as artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS) analysis during micro-channel fabrication on silica glass. A comparative analysis of FLC, ANN as well as ANFIS has been performed and experimental error prediction has been propounded to estimate minimum error possibilities such as mean absolute error (MAE), root mean square error (RMSE) and regression value (R). Computational time training dataset, minimum sample size and prediction time are also illustrated in this paper. In this paper, ANN, FLC and ANFIS models are analyzed for tool wear rate (TWR) and heat-affected zone (HAZ). 3D Rule Viewer and regression analysis as well as validation of test results and characteristics graph between performances with number of epochs of ANN model also are included in this paper for TWR and HAZ. Influence of process parameters like voltage, duty ratio, pulse frequency and electrolyte concentration on Surface Viewer of TWR and HAZ is also illustrated. It is found that ANFIS has great effectiveness of prediction of error during micro-ECDM process.

Investigating discharge and material removal mechanisms in graphite powder-mixed ECDM

ABSTRACT Graphite powder mixed electrochemical discharge machining (GPM-ECDM) is an effective technique for micromachining of hard and brittle nonconductive materials. To reveal the mechanisms of discharge and material removal in GPM-ECDM the voltage and current signals obtained in the electrolyte with and without graphite powder were experimentally investigated, and it was observed that there were two types of discharges in the GPM-ECDM. The influences of adding graphite powder to the electrolyte on the machining of microcraters and microgrooves were studied. The analysis of the machining results revealed that the workpiece material was removed by both the general electrochemical discharge and the discharge occurring on the graphite powder. Compared to the machined surface obtained in conventional electrolyte, the surface roughness decreased by 30–56% when using the graphite powder mixed electrolytes with particle diameters of 1 μm or 18 μm.

Process capability of electrochemical discharge machining: A review

Electrochemical discharge machining (ECDM) is a hybrid machining formed by combining the principles of electrochemical machining and electrical discharge machining. The ECDM is unconventional micromachining that can fabricate holes, blind holes, micro-cavities and grooves on brittle insulating materials such as quartz, glass, silicon wafers and different composites that are difficult to machine. These non-conducting materials have sundry applications such as Micro Electric-Mechanical Systems, biomedical and electronics items. The ECDM provides maximum material removal rate and good surface quality with minor tool wear. The study describes how different process parameters affect machining. The assessment mainly focuses on various tool electrode geometries and materials that are used in ECDM. The present article investigates the ramifications of different types of electrolytes and additives mixed in electrolytes used during the ECDM process on the machined zone. This paper comprehensively reviews the effect of change in applied voltage, machining gap and an inter-electrode gap in the ECDM and it also analyses the fabrication of different materials including glass, quartz, ceramics and composites.

Ultrasonic Vibration-assisted Electrochemical Discharge Machining of Quartz Wafer Micro-Hole Arrays

The micro-hole machining of quartz wafers depends on photolithography techniques akin to those used in semiconductor fabrication. These methods present challenges due to high equipment setup costs, large space requirements, and environmental pollution risks. This research applies ultrasonic vibration assistance in electrochemical discharge machining to create an array of micro-holes on quartz wafers. In the experiments, a self-prepared tungsten carbide micro-electrode array served as the tool electrode. This electrode was a 2 × 2 square array, with needles measuring 30 × 30 μm. A series of experiments was conducted to investigate the effects of various machining parameters, including working voltage, feed rate, duration time, duty factor, and ultrasonic power level, on the characteristics of the micro-hole array. The characteristics included average hole diameter and through-hole surface morphology. The experimental objective was to achieve a through-hole diameter of 80 μm with an accuracy of ±8 μm. During the electrochemical discharge machining, suitable ultrasonic vibrations can thin the insulating gas film coating on the electrode surface, resulting in a more uniform gas film. As the insulating gas film’s thickness decreased, so did the critical voltage needed for the electrochemical discharge machining, reducing the hole’s diameter expansion. The ultrasonic vibration assistance can enable the satisfaction of the dimensional accuracy requirement. The experimental results indicate that ultrasonic vibration assistance can effectively improve the processing capacity and reduce sample fragmentation. A working voltage of 44 V, feed rate of 1 μm/6 s, duration time of 30 μs, duty factor of 30%, and ultrasonic power level of 1 resulted in better inlet and outlet surface morphology without outlet fragmentation. Moreover, the average diameters of the inlet and outlet were roughly 80 μm while meeting the through-hole diameter of 80 μm with accuracy of ±8 μm.

Discharge Characteristics and Mechanisms of Electrolytic Discharge Processing by Jet Mask

As a novel microfabrication method, electrochemical discharge machining has remarkable effects on the forming and processing of brittle and hard materials and non-conductive materials, but little research has been done on the electrochemical discharge mode in the jet state. To fulfil the potential of this technology, innovative research on the discharge characteristics and mechanism of electrochemical discharge machining in the jet mask is proposed. A high-speed camera observation experiment was set up to record the process of the jet flow column discharge formation and penetration. Changes in the electric field of the electrolytic jet channel were analysed by simulation software, and the morphology of the machined micro-pits was observed using a microscope. A mathematical derivation of the dielectric electric field in the gas–liquid two-phase jet column reveals the mechanism of discharge channel formation in the jet state. The experiments show that when the processing voltage is 400 V, a stable continuous spark appears, realizing the unique characteristics of a large-gap long-distance discharge and a flat small circle-shaped discharge mark produced at the bottom of the crater. The actual field strength within the bubble of this model obtained by mathematical derivation is approximately 61.5 kV/cm greater than the critical field strength for air bubble breakdown in the standard state, where bubble breakdown occurs in the discharge.

Process characteristics of electrochemical discharge machining and hybrid methods: a review

Process characteristics of electrochemical discharge machining and hybrid methods: a review

Experimental Investigation of the Machining Characteristics in Graphite-Powder-Mixed Electrochemical Discharge Machining of Microholes in Glass.

The effect of graphite powder on the machining characteristics in graphite-powder-mixed electrochemical discharge machining of microholes was still not clear. How the discharge mechanism changed with the addition of graphite powder into the electrolyte, which further led to changes in the morphology of the machined holes, remained to be revealed. In this study, a series of microhole machining experiments were conducted in glass. Comparisons of the discharge energy, microhole entrance diameter, hole taper, and tool electrode morphology after machining were made when machining in the electrolytes with and without graphite powder. Experimental results revealed that there were a lot of small pulse currents distributed on the current waveform when machining with the graphite-powder-mixed electrolyte. The average discharge energy of the small pulse current was 2.8 times as much as that of the general electrochemical discharge. After introducing graphite powder into the electrolyte, the entrance diameter of the hole became larger when the hole depth was deeper than 200 μm. The HAZ width increased with increasing hole depth at the voltage of 37-41 V, while it decreased at the voltage of 43 V. A reduction in hole taper angle with a range of 0.5° to 2.3° was achieved. In addition, after machining in electrolytes with and without graphite powder, the tool electrode surfaces showed different morphologies due to different discharges.

Study on electrochemical discharge machining of small holes array on glass with ultrasonic vibrating tube electrode

Study on electrochemical discharge machining of small holes array on glass with ultrasonic vibrating tube electrode

Dimensional accuracy enhancement of machined-hole through UAECDM-process under the magnetic-field-assistance

ABSTRACT Electrochemical discharge machining (ECDM) is a micro-machining hybrid technique that utilizes electrical discharge and electrochemical machining principles. However, the issue of insufficient electrolyte in the hydrodynamic region hinders the continuation of the machining action. Although ultrasonic tool vibrations have been used to overcome this problem to some extent, the excessive mechanical energy produced by high-amplitude tool vibration may lead to surface crack formations. As a result, the present work employs two flushing improvement methods, namely the ultrasonic vibrations and magnetic filed assistances, in the ECDM process. A comparative study has been performed to identify the effect of the magnetic field on discharge quality. The material removal rate and depth of penetration were increased by 11% and 24%, respectively, and the observed reduction in hole overcut and taper angle was around 35% and 50%, respectively. Optical microscope images quantified improvement in dimensional accuracy and decreased HAZ area.