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1
Liu, Yong, Chao Zhang, Songsong Li, Chunsheng Guo, and Zhiyuan Wei. "Experimental Study of Micro Electrochemical Discharge Machining of Ultra-Clear Glass with a Rotating Helical Tool." Processes 7, no. 4 (2019): 195. http://dx.doi.org/10.3390/pr7040195.
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Electrochemical discharge machining (ECDM) is one effective way to fabricate non-conductive materials, such as quartz glass and ceramics. In this paper, the mathematical model for the machining process of ECDM was established. Then, sets of experiments were carried out to investigate the machining localization of ECDM with a rotating helical tool on ultra-clear glass. This paper discusses the effects of machining parameters including pulse voltage, duty factor, pulse frequency and feed rate on the side gap under different machining methods including electrochemical discharge drilling, electrochemical discharge milling and wire ECDM with a rotary helical tool. Finally, using the optimized parameters, ECDM with a rotary helical tool was a prospective method for machining micro holes, micro channels, micro slits, three-dimensional structures and complex closed structures with above ten micrometers side gaps on ultra-clear glass.
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VIPIN, CHOPADE DHANANJAY PISE PANDIT SHINDE. "STATISTICAL ANALYSIS OF ELECTROCHEMICAL DISCHARGE MACHINING FOR SODA LIME GLASS." JournalNX - A Multidisciplinary Peer Reviewed Journal 3, no. 8 (2018): 14–19. https://doi.org/10.5281/zenodo.1158334.
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Electro chemical discharge machining (ECDM) is a hybrid process which combines the features of electro chemical machining (ECM) and electro discharge machining (EDM).The need for micromachining of advanced engineering materials started increase in demand in various sectors like nuclear, aerospace and medical industries. Electrochemical discharge machining (ECDM) technique is that involves high-temperature melting and accelerated chemical etching under the high electrical energy discharged and has potential to machine electrically non-conductive materials such as glass, quartz, composite, ceramics.
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VIPIN, CHOPADE, PISE DHANANJAY, and SHINDE PANDIT. "STATISTICAL ANALYSIS OF ELECTROCHEMICAL DISCHARGE MACHINING FOR SODA LIME GLASS." JournalNX - a Multidisciplinary Peer Reviewed Journal 3, no. 8 (2017): 14–19. https://doi.org/10.5281/zenodo.1420769.
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Electro chemical discharge machining (ECDM) is a hybrid process which combines the features of electro chemical machining (ECM) and electro discharge machining (EDM).The need for micromachining of advanced engineering materials started increase in demand in various sectors like nuclear, aerospace and medical industries. Electrochemical discharge machining (ECDM) technique is that involves high-temperature melting and accelerated chemical etching under the high electrical energy discharged and has potential to machine electrically non-conductive materials such as glass, quartz, composite, ceramics. In ECDM, gas film and sparks are generated on a tool when voltage is applied between the tool and a counter electrode. Work-piece materials are removed mainly by the heat of the sparks. The spark generation is affected by both the voltage and electrolyte conditions. In this present work, The effect of process variables such as electrolyte concentration (EC), duty factor (DF), voltage (V), on response parameters such as Material Removal Rate (MRR), Tool Wear Rate (TWR), Diametric overcut (DOC) have been investigated sodalime glass in electrochemical discharge machining (ECDM) using tungsten carbide electrode. Analysis of variance (ANOVA) and F-test were performed to determine the significant parameters at a 95% confidence interval. https://journalnx.com/journal-article/20150415
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Li, Xiaokun, Yuankai Ren, Zhiyuan Wei, and Yong Liu. "Development of Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining Tool." Recent Patents on Mechanical Engineering 12, no. 4 (2019): 313–25. http://dx.doi.org/10.2174/2212797612666190808101736.
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Background: The fabrication of microstructures with high machining quality is always difficult when it is concerned with non-conductive hard and brittle materials such as glass and engineering ceramics. It is reported in related papers and patents that Electrochemical Discharge Machining (ECDM) process is a good choice for machining non-conductive, hard and brittle materials. However, the machining performance of ECDM process, especially in the aspect of geometric accuracy and surface quality, needs to be greatly improved. Objective: The purpose of this study was to improve the machining quality of conventional ECDM process by introducing ultrasonic vibration to ECDM process, develop an Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining (UAECDM) tool, and investigate the improvements of the machining performance by means of comparative experiments. Methods: Firstly, the machining principle of UAECDM was investigated, and the effects of ultrasonic vibration are discussed with the analysis of the micro process. Secondly, the hardware system, which consists of a machine tool body, XY and Z axes, an ultrasonic spindle system and motion control system, was established; and the software system was developed based on the analysis of the overall workflow of the machining process. Finally, comparative experiments, including ECDM drilling, UAECDM drilling, ECDM milling and UAECDM milling, were carried out to reveal the improvements of the machining quality. Results: In the UAECDM group, a micro-hole with the inlet diameter of 133.2µm as well as the 3 × 3 array of micro holes was fabricated on the glass workpiece with 300µm thickness, and a microgroove with the width of 119.2µm was successfully milled on the glass workpiece. It is shown in both microscopic photographs and optical measurements that the microstructures fabricated by UAECDM have better machining quality compared with similar microstructures fabricated by ECDM. Conclusion: Based on comparative experiments and discussions of the results, it has been proved that the machine tool can meet the requirement of the ultrasonic vibration-assisted micro electrochemical discharge machining and can improve the geometric accuracy and surface quality significantly.
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Liu, Jiangwen, Zhibiao Lin, Zhongning Guo, Shuzhen Jiang, Taiman Yue, and Xiaolei Chen. "A Study of the Materials Removal Mechanism of Grinding-Aided Electrochemical Discharge Machining of Metal Matrix Composites." Advanced Composites Letters 27, no. 5 (2018): 096369351802700. http://dx.doi.org/10.1177/096369351802700504.
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In order to research the workpiece materials removal mechanism of Grinding-assisted Electro-chemical Discharge Machining(G-ECDM) of Metal Matrix Composites (MMCs), a good deal of single pulse experiments has been performed in this paper. The crater volume, convex edge, debris, machined surface of G-ECDM have been taken into considerationand it turns out to be that the grinding effect removes the convex edge of the Electro-chemical Discharge Machining (ECDM) crater during the machining of MMCs, the result show that the material removal rate (MRR) of G-ECDM is much higher than that of ECDM and Electrical Discharge Machining (EDM). When compared to the normal ECDM process, it is found that though the Al4C3 phase can be detected in this ECDM condition, no Al4C3 are observed in the processed surface, which indicates a better surface quality. The reason of this phenomenonhas been analyzed theoretically and experimentally. Based on these results, mechanism of the G-ECDM of MMCs was disclosed in this study.
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Lu, Chang Jian, An Gu, Li Meng, and Sheng Yi Yang. "The Micro-Milling Machining of Pyrex Glass Using the Electrochemical Discharge Machining Process." Advanced Materials Research 403-408 (November 2011): 738–42. http://dx.doi.org/10.4028/www.scientific.net/amr.403-408.738.
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The principles of ECDM and micro-milling were described in the article. The ECDM technology and micro-milling technology were combined, and a milling platform was designed, through the analysis of the affecting factors in the processing, the Pyrex glass was machined by using the electrochemical discharge micro-milling machining and the experiment results were discussed. The results showed that the electrochemical discharge milling machining had a good prospect for the micro machining of the non-conductive materials.
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Coteaţă, Margareta, and Gheorghe Creţu. "ECDM Drilling Process Analysis via Taguchi Method." Applied Mechanics and Materials 657 (October 2014): 337–41. http://dx.doi.org/10.4028/www.scientific.net/amm.657.337.
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Electrochemical discharge machining (ECDM) is based on synergetic action of anodic dissolution with erosive effect of electrical discharges in material removal process. Drilling by ECDM can be applied for hard to be cut materials, when no drilling by cutting or no EDM machine is available.
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Arya, Rajendra Kumar, Shivangi Paliwal, Akshay Dvivedi, and Rajakumaran Maran. "Investigation on Deposition of the Machined By-Products and Its Reduction during Electrochemical Discharge Machining (ECDM)." Journal of The Electrochemical Society 169, no. 2 (2022): 023506. http://dx.doi.org/10.1149/1945-7111/ac4f6f.
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Electrochemical action and subsequent discharges are utilized in electrochemical discharge machining (ECDM) for the fabrication of components by subtracting the undesired material. However, as the process progresses, localized electrolyte vaporization (machining zone) and its leading effects limit the process performance. Controlled delivery of fresh electrolyte into the machining zone to replenish the vaporized electrolyte improves the ECDM process performance, utilized in the electrolyte injection-ECDM (EI-ECDM) process. Apart from the control strategies, the literature lacks a detailed investigation of the phenomena involved in deteriorating the ECDM’s machining performance. Few researchers enlighten that the deposition of the machined by-products on the tooltip might be a significant reason. Therefore, the present work is carried out to investigate the influence of deposition of the machined by-products on outcomes of the ECDM process at different parametric conditions. Various scientific tools and techniques are used to explore the underlying phenomena of machined by-products deposition. It shows that deposition significantly alters the geometry, surface texture, and properties of tool-electrode, which intern affects the ECDM’s performance. Further, experimental results and subsequent characterization reveal that EI-ECDM can significantly control the deposition and enhance the process performance. Thus, a multi-response optimization was performed to increase the applicability of the EI-ECDM process.
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Wu, Kun Ling, Hsin Min Lee, and Kuan Hwa Chin. "Application of Electrochemical Discharge Machining to Micro-Machining of Quartz." Advanced Materials Research 939 (May 2014): 161–68. http://dx.doi.org/10.4028/www.scientific.net/amr.939.161.
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Electrochemical discharge machining (ECDM) is the preferred non-traditional process technology in recent years, The main processing is applied to machining non-conductive hard brittle materials. This study investigated the precision and stability of quartz fabricated by ECDM and explored the optimal processing parameters including size of electrode, machining speed as well as pulse-on and pulse-off duration. Microgrooves machined under the optimal processing parameters with adjusted rotational speed and feed rate were examined to understand the effect of different ECDM parameters on machining performance. The results indicate that micro-holes of better morphology could be obtained under pulse voltage of 40 V, electrolyte concentration of 5 M, electrode size of 125 μm. Moreover, rotational speed of 1500 rpm and pulse-on/pulse-off (ms) ratio of 1:0.6 gave higher machining accuracy with smaller hole diameter and shorter machining time. Finally, microgrooves machined under the optimal processing parameters showed the best accuracy in dimension and cross-sectional morphology at rotational speed of 2500 rpm, pulse-on /pulse-off (ms) ratio of 1:1.6, and feed rate of 3000 μm/min.
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PAWAR, Pravin, Amaresh KUMAR, and Raj BALLAV. "DEVELOPMENT AND MANUFACTURING OF ARDUINO BASED ELECTROCHEMICAL DISCHARGE MACHINE." Journal of Machine Engineering Vol.18, No.1 (2018): 46–61. http://dx.doi.org/10.5604/01.3001.0010.8822.
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The machining of non-conducting materials is very difficult due to its brittleness and hardness properties. The electrochemical discharge machining (ECDM) process is the hybrid non-traditional manufacturing technology because it is combined with two processes namely electro-chemical machining (ECM) and electro-discharge machining (EDM) which can cut non-conducting and conducting materials. Hence from this view, the present work is undertaken to understand the development and manufacturing of ECDM setup based on Arduino. The 2D drawings are drawn by using AutoCAD software and 3D model is developed with CATIA software. The ECDM machine setup is manufactured accurately according to the 2D drawings and 3D model. The gravity feed mechanism is applied to workpiece materials and the speed of cathode tool electrode is controlled by using Arduino programming through the computer. The preliminary experimental trials were carried out and micro-hole drills on the glass and ceramic materials are successfully achieved. The present article provides fundamental and detailed building study of ECDM setup which includes information from the starting sketch up to the real prototype model. This work may be useful to make advanced machining setup as well as may solve the basic difficulties of new researchers in this field.
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Liu, Jiang Wen, Guang Xue Chen, Tai Man Yue, and Zhong Ning Guo. "Single Pulse Study of Electrochemical Discharge Machining of Metal Matrix Composites." Applied Mechanics and Materials 200 (October 2012): 536–39. http://dx.doi.org/10.4028/www.scientific.net/amm.200.536.
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Single pulse experiments were conducted to study electrochemical discharge machining (ECDM) of particulate reinforced metal matrix composites (MMCs) which are widely used in the packaging industry. This article reports the first phase of this study with an emphasis on the effects of pulse current on crater volume. The results showed that all the ECDM craters have a circular shape surrounded by a rim of re-solidified material. This indicates that ECDM craters were created by arc effect. The craters produced by both electrical discharge machining (EDM) and ECDM increased in volume with increasing peak current. However, within the range of currents studied, the craters formed by ECDM were always smaller than those produced by EDM alone under the same current. Moreover, the crater volume difference between EDM and ECDM did not change considerably with increasing current. This is considered to be due to an increase in ECDM current mainly enhances the arc energy and has little effect on the ECM action. Furthermore, the experiment results showed that the efficiency of the arc action in ECDM is reduced when the percent of reinforcement phase is increased.
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Huang, Shao Fu, Di Zhu, Yong Bin Zeng, Wei Wang, and Yong Liu. "Micro-Hole Machined by Electrochemical Discharge Machining (ECDM) with High Speed Rotating Cathode." Advanced Materials Research 295-297 (July 2011): 1794–99. http://dx.doi.org/10.4028/www.scientific.net/amr.295-297.1794.
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Electrochemical discharge machining (ECDM), based on electrochemical machining (ECM) and electrodischarge machining (EDM), is an unconventional micro-machining technology. In this paper, with the use of water, the process of micro hole on ANSI 304 stainless steel machined by micro-ECDM with high speed rotating cathode is studied. The effects of machining conditions such as the cathode rotating speed and cathode diameter on the surface quality and accuracy of the shape are investigated. The results indicate that a relatively higher electrode rotating speed can improve the machining accuracy of the micro-holes and reduce the electrodes wear.
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Tang, Weidong, Yuhao Zhu, Xiaoming Kang, and Cong Mao. "Experimental Investigation of Discharge Phenomena in Electrochemical Discharge Machining Process." Micromachines 14, no. 2 (2023): 367. http://dx.doi.org/10.3390/mi14020367.
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Electrochemical discharge machining (ECDM) is a promising non−traditional processing technology used to machine non−conductive materials, such as glass and ceramic, based on the evoked electrochemical discharge phenomena around the tool electrode. The discharge in ECDM is a key factor that affects the removal of material. Moreover, the discharge current is an important indicator reflecting the discharge state. However, the discharge characteristics remain an open topic for debate and require further investigation. There is still confusion regarding the distinction of the discharge current from the electrochemical reaction current in ECDM. In this study, high−speed imaging technology was applied to the investigation of the discharge characteristics. By comparing the captured discharge images with the corresponding discharge current, the discharge can be classified into three types. The observations of the discharge effect on the gas film indicate that a force was exerted on the gas film during the discharge process and the shape of the gas film was changed by the force. In addition, the energies released by different types of discharge were calculated according to the voltage and current waveforms. The discharge frequency was found to increase with the increase in applied voltage and the frequency of the second type of discharge was approximately equal to that of the third type when the applied voltage was higher than 40 V.
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Yang, Chun-Hao, Shao-Hua Yu, and Hai-Ping Tsui. "Observation of Gap Phenomena and Development Processing Technology for ECDM of Sapphire." Processes 12, no. 6 (2024): 1149. http://dx.doi.org/10.3390/pr12061149.
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The main purpose of this study was to develop observation techniques and processing technology for the electrochemical discharge machining (ECDM) of sapphire wafers. To measure the effect of gas-film thickness, discharge-spark conditions, and droplet sliding frequency on machining quality and efficiency in ECDM, this research utilized high-speed cameras to observe the gas film thickness and formation of the gas film during ECDM. Additionally, this study observed the machining-gap phenomena during ECDM. The formation mechanism and machining characteristics of the gas film were understood through experiments. The machining parameters included the liquid level, working voltage, rotation speed, and duty factor. This study analyzed and discussed the effect of each machining parameter on the gas-film thickness, current, electrode consumption, and droplet sliding frequency. Moreover, this study aimed to obtain optimized machining parameters to overcome the difficulty of machining sapphire. The experimental results indicated that utilizing a high-speed camera to capture the phenomena between electrodes during electrochemical discharge could effectively observe the gas-film thickness and the coverage of the gas film. A higher bubble coalescence rate enhanced the machining capability and reduced the lateral discharge. Therefore, this study could obtain better machining-hole depths through observation and analysis to improve gas-film stability and machining capability. This study demonstrated that a liquid level of 700 µm, a working voltage of 48 V, a duty factor of 50%, and a tool electrode rotational speed of 200 rpm could achieve a hole depth of 86.7 µm and a hole diameter of 129.5 µm.
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VIPIN, CHOPADE, PISE DHANANJAY, NIGADE MAHESH, and PATIL YOGESH. "OPTIMIZATION OF PROCESS PARAMETERS OF ELECTROCHEMICAL DISCHARGE MACHINING USING SDS POWDER." JournalNX - A Multidisciplinary Peer Reviewed Journal 3, no. 4 (2017): 227–33. https://doi.org/10.5281/zenodo.1460274.
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Electrochemical discharge machining (ECDM) is an emerging non-traditional processing technique that involves high-temperature melting and accelerated chemical etching under the high electrical energy discharged and has potential to machine electrically non-conductive materials such as glass, quartz, composite, ceramics. In ECDM, gas film and sparks are generated on a tool when voltage is applied between the tool and a counter electrode. Work-piece materials are removed mainly by the heat of the sparks. https://journalnx.com/journal-article/20150321
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Paul, Lijo, and Somashekhar S. Hiremath. "Characterisation of Micro Channels in Electrochemical Discharge Machining Process." Applied Mechanics and Materials 490-491 (January 2014): 238–42. http://dx.doi.org/10.4028/www.scientific.net/amm.490-491.238.
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Micromachining techniques has increased the demand for precise and accurate instruments which are used in many industries. Glass materials offer higher challenges in micro machining as they are tough, non-conducting and difficult to machine with conventional machining operations. Electro Chemical Discharge Machining (ECDM) is a new non-conventional hybrid machining process which combines the features of Electrical Discharge Machining (EDM) and Electro Chemical Machining (ECM) to machine both conducting and nonconducting materials. In the present paper effect of various process parameters like voltage, concentration of electrolyte, duty factor and temperature on ECDM process are studied to obtain desired micro channels in soda lime glass. Design of Experiment (DOE) is used to plan and conduct the experiments. The Response Surface Modelling (RSM) is used for characterising non linear output responses in terms of material removal rate and surface finish. Modeled results are validated with experimental values.
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Zhao, Douyan, Zhaoyang Zhang, Hao Zhu, Zenghui Cao, and Kun Xu. "An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material." Micromachines 12, no. 1 (2020): 22. http://dx.doi.org/10.3390/mi12010022.
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Electrochemical discharge machining (ECDM) and laser machining are emerging nontraditional machining technologies suitable for micro-processing of insulating and hard-brittle materials typified by glass. However, poor machinability of glass is a major constraint, which remains to be solved. For the micro-grooves processed by ECDM, the bottom surface is usually uneven and associated with protrusion structures, while the edges are not straight with obvious wave-shaped heat-affected zones (HAZs) and over-cutting. Besides, the cross section of the micro-grooves processed by the laser is V-shape with a large taper. To solve these problems, this study proposed the laser-assisted ECDM for glass micro-grooving, which combines ECDM and laser machining. This study compared morphological features of the single processing method and the hybrid processing method. The results show that ECDM caused cylindrical protrusions at the bottom of the microgrooves. After processing these micro-grooves by laser, the cylindrical protrusions were removed. However, the edge quality of the microgrooves was still poor. Therefore, we used the laser to get microgrooves first, so we got micro-grooves with better edge quality. Then we use ECDM to improve the taper of microgrooves and the cross-sectional shape of the microgrooves transformed from a V-shape to a U-shape.
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Rashedul, Islam Md, Yan Zhang, Kebing Zhou, Guoqian Wang, Tianpeng Xi, and Lei Ji. "Influence of Different Tool Electrode Materials on Electrochemical Discharge Machining Performances." Micromachines 12, no. 9 (2021): 1077. http://dx.doi.org/10.3390/mi12091077.
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Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.
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Arab, Julfekar, and Shih-Chi Chen. "Micro-Fabrication of PMMA Using Electrochemical Discharges." ECS Meeting Abstracts MA2024-01, no. 44 (2024): 2483. http://dx.doi.org/10.1149/ma2024-01442483mtgabs.
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The Poly (methyl methacrylate)-PMMA material also recognized as acrylic is an significant material for the different microsystem’s technologies. PMMA properties such as optical transparency, high hydrophilicity, biocompatibility, chemical inertness and lower autofluorescence, makes it a suitable candidate for the microfluidics devices These devices consist of the various micro-features i.e., micro-holes as well as the micro-channels. In current times, fabrication methods such as laser machining, hot embossing, injection molding, and mechanical cutting are predominantly used for the microfabrication in PMMA material. Nonetheless, the major processes such as laser machining and mechanical cutting exhibit some limitations due to issues like higher processing+setup costs, higher thermal damage, edge burr formations etc. Recently, a method i.e. machining with electrochemical discharges emerged as the potential alternative to the existing methods to machine the PMMA substrates. This method also called ‘electrochemical discharge machining (ECDM)’ considered to be the hybrid combination of microfabrication based on electric-discharge and electro-chemical processes. ECDM is a relatively simple, economical process which, in principle, can perform micro-fabrication in various materials irrespective of its electrical-conductivity, hardness as well as brittleness. In ECDM heat energy generated by electrochemical (EC) discharges in an electro-chemical cell (consists of a micro tool rod/electrode, a big-sized counter electrode and an aqueous alkaline electrolyte). In ECDM process, when voltage (>2 V) is provided between the smaller size tool (cathode) and bigger counter electrode (anode) which are kept in the aqueous KOH. The applied voltage results in the electrolysis of aqueous KOH electrolyte and produces gas bubbles of hydrogen (H2) at cathode point and of oxygen at anode point respectively. At the point of cathode (tool electrode) gas bubble production is very higher due to higher current density at the smaller tool surface. The subsequent increase in the applied voltage starts the process of merger of bubble which forms an envelope of gas film around the smaller tool electrode. At this stage, tool electrode gets complete isolation from surrounding electrolyte. Breakage of this gas film envelope happens at elevated voltage (> 24±0.1 V) and discharges are generated which produces heat energy. The material removal from the PMMA workpiece happens which is kept below the discharge producing tool. The material removal is result of melting, evaporation and etching due to heat energy. The most of research on ECDM is demonstrated for the glass and alumina ceramics in past decade which are electrically nonconductive workpieces. Nevertheless, the ECDM process has not been completely explored for the polymers, such as PMMA. Bhargav et al. have recently explored this process for the micro-channel formation in PMMA using NaOH electrolyte with 0.7 mm titanium tool electrode having cylindrical shapes. It is very much clear from the known literature that work related to PMMA micro-structuring using ECDM is scarce. Furthermore, the experimental analysis was directed on the micro-channel (> 700 µm) formation only. Consequently, there is a wide research gap for micro-structuring of PMMA for formation miniaturized micro-holes (> 300 µm) of different shapes such as circular, slotted. Analysing EC discharge behaviour, tool electrode condition, and micro-hole geometric features are the key tasks which are performed. The present work is performed to investigate the EC discharge behaviour and identification of the appropriate applied voltage on the micro-hole formation as well as the geometric characteristics such as hole size, depth, heat affected zone (HAZ) and circularity. Also, the tool condition after usage and its effect on the EC discharges and micro-hole quality have also been explored. The identification of Vc i.e. critical voltage has been carried out. The EC discharges stability for the range of applied voltage has been analyzed. It has been found that the applied voltage needed for the appropriate machining quality with uniform EC discharges should be in the range of Vc+4 to Vc+6. The lower values of applied voltage Vc+2 indicated the region of the unstable and non-uniform EC discharges affecting the micro-hole quality. The worn-out tool also affects the hole quality and EC discharge stability. Figure 1
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Vikrant, Sharma, and Kumar Sunil. "Experimental research to Optimize Process Parameters in Machining of Non Conducting Material with hybrid non conconventional machining." International Journal of Trend in Scientific Research and Development 1, no. 4 (2017): 107–16. https://doi.org/10.31142/ijtsrd84.
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Among all non conventional micro machining, electrochemical discharge machining ECDM is having high quality of material removal rate with zero residual stress. This machining has been accepted as a highly modern technology in micromachining. In this paper an effort has been done on micro drilling of glass using electrochemical discharge machining ECDM . A fixed tool and a step down transformer have been used to support the steady machining to increase the accuracy of work piece. The input parameters used in this experiment are voltage, concentration of electrolyte, enter electrode gap and ratio of area of electrode. MRR has been investigated over the input parameters. Feed rate and electrolyte temperature has been made constant of 3µm sec and 30°c respectively. Taguchi method is used to optimize the effect of the process parameters on MRR. The signal to noise S N ratio and the ANOVA analysis are employed to find the contributions of input parameters. Vikrant Sharma | Sunil Kumar "Experimental research to Optimize Process Parameters in Machining of Non Conducting Material with hybrid non conconventional machining" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: https://www.ijtsrd.com/papers/ijtsrd84.pdfAmong all non conventional micro machining, electrochemical discharge machining ECDM is having high quality of material removal rate with zero residual stress. This machining has been accepted as a highly modern technology in micromachining. In this paper an effort has been done on micro drilling of glass using electrochemical discharge machining ECDM . A fixed tool and a step down transformer have been used to support the steady machining to increase the accuracy of work piece. The input parameters used in this experiment are voltage, concentration of electrolyte, enter electrode gap and ratio of area of electrode. MRR has been investigated over the input parameters. Feed rate and electrolyte temperature has been made constant of 3µm sec and 30°c respectively. Taguchi method is used to optimize the effect of the process parameters on MRR. The signal to noise S N ratio and the ANOVA analysis are employed to find the contributions of input parameters. Vikrant Sharma | Sunil Kumar "Experimental research to Optimize Process Parameters in Machining of Non Conducting Material with hybrid non conconventional machining" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: https://www.ijtsrd.com/papers/ijtsrd84.pdf
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Liu, Jiangwen, Qinming Huang, Ming Wu, et al. "Electrochemical Discharge Grinding of Metal Matrix Composites Using Shaped Abrasive Tools Formed by Sintered Bronze/diamond." Science and Engineering of Composite Materials 27, no. 1 (2020): 346–58. http://dx.doi.org/10.1515/secm-2020-0038.
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AbstractElectrochemical discharge machining (ECDM) is a well-known process for machining of particulate reinforced metal matrix composites (MMCs). However, ECDM process suffers several drawbacks such as the lower material removal rate (MRR), high risks of tool wear rate (TWR) and relatively poor surface quality, etc. This study proposes a kind of electrochemical discharge grinding machining (ECDGM) method which employs a special shaped tool electrode. During the process, not only the can the hybrid action of electrochemical dissolution, spark erosion, and abrasive grinding improve the performance of machining MMCs, but also the special shaped of the tool electrode can be used to discharge the machined debris. And thus a higher machining efficiency and lower TWR can be obtained. The performance of developed process was conducted on machining of SiC particulate reinforced aluminum workpiece. The role of peak curre+nt, pulse duration, duty cycle, rotary speed and abrasive grit size has been investigated on MMR and TWR using the nonabrasive round electrode, abrasive round electrode, and abrasive shaped electrode respectively. The experimental results showed that using the shaped abrasive electrode for machining MMCs can achieve a higher MRR and lower TWR, as compared to the non-abrasive round electrode, abrasive round electrode. Besides, the orthogonal method was employed to analyze the relative importance of the machining parameters on MRR and TWR, it has been observed that MRR is affected by the processing parameters following the order of rotary speed > peak current > duty cycle > pulse duration, and TWR is following the order of peak current > duty cycle > pulse duration > rotary speed.
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Jia, Zhixin, Kaiyue Zhang, and Jin Wang. "Surface Quality of Al2O3 Ceramic and Tool Wear in Diamond Wire Sawing Combined with Oil Film-Assisted Electrochemical Discharge Machining." Applied Sciences 13, no. 15 (2023): 9030. http://dx.doi.org/10.3390/app13159030.
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Diamond wire sawing is one of the most widely used methods of cutting Al2O3 ceramic because it has good machining accuracy and causes less surface damage. However, its material removal rate (MRR) needs to be improved with the increasing demand for Al2O3 ceramic parts. In this paper, spark discharges are generated around the diamond wire based on the electrochemical discharge machining (ECDM) process. An oil film-assisted ECDM process is applied to solve the difficulty of generating spark discharges when the thickness of the workpiece exceeds 5.0 mm due to the difficulty of forming a hydrogen gas film. Experimental results show that the combination of oil film-assisted ECDM and diamond wire sawing improved the MRR of Al2O3 ceramic. Oil film-assisted ECDM may improve the surface quality of machined parts and reduce the wear on diamond wire. Therefore, this research focuses on the surface quality of Al2O3 ceramic and tool wear in diamond wire sawing combined with oil film-assisted ECDM. Surface roughness and topography, recast layer, and elements of the machined surface are analyzed. The tool wear is studied using SEM images of diamond wire. The results provide a valuable basis for application of diamond wire sawing combined with oil film-assisted ECDM.
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Arab, Julfekar, and Shih-Chi Chen. "Study of Behavior of EC Discharges during PMMA Machining by ECDM Process." ECS Meeting Abstracts MA2024-02, no. 56 (2024): 3742. https://doi.org/10.1149/ma2024-02563742mtgabs.
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Poly (methyl methacrylate)-PMMA material is an essential and useful material for the majority of microfluidic devices. The superior properties of PMMA, namely, optical transparency, biocompatibility and chemical inertness make the PMMA a worthy candidate for microfluidic devices. Micro-holes are one of the significant micro-features used in microfluidic devices fabricated in PMMA material. The various techniques of PMMA machining includes laser machining, hot embossing, injection molding, and mechanical cutting. Nevertheless, the usage of such processes is limited due to limitations such as higher cost, processing difficulties and machining quality. In recent times, the electrochemical discharge machining (ECDM) process has emerged as a efficient process for machining electrically non-conductive material such as glass, alumina etc. The present work is an attempt to perform micromachining in PMMA using the ECDM process. The primary mechanism of material removal in ECDM process consists of exhaustive and elevated temperature heating of the PMMA material due to the electrochemical (EC) discharges occurring at tool electrode tip in the EC region that leads to melting as well as vaporization of the material. Furthermore, the increment in the local machining region temperature enhances the rate of chemical etching which produces the smoother sidewalls of the microfeatures. The work material-PMMA, stainless steel tool electrode is kept in the close vicinity of each other in an electrochemical cell which also includes aqueous KOH electrolyte with counter ring electrode. The micro-hole quality factors such as size, depth, circularity etc. depend on the heat energy produced by EC discharges. Hence, the behavior of EC discharges greatly affects the machining process and micro-hole quality and it’s study is critical in order to achieve the micro-holes of appropriate quality for different microfluidic applications. The heat energy(q) generated, and EC discharges behavior depends majorly on the applied voltage (Va) and mean EC discharge current (Id). EC discharge behavior was evaluated by analyzing the Id values, the discharge frequency (f) with the help of current-time graphs which show the current peak stabilities and uniformities. Moreover, the stable and unstable EC discharge zones were also identified using the electrolysis current, discharge current and Va values recorded during the actual machining. The Va values up to 26 V indicated the instability region of EC discharges. The current peaks recorded for 26 V indicated the non-uniformity resulting in the micro-holes with inferior quality (higher size, lower depth, less circularity). The Va values greater than 28 V showed a higher stability as well as uniformity of EC discharges. Based on the outcome of the experimental results, superior quality micro-holes of varied sizes have been fabricated and characterized. The appropriate quality micro-holes of average opening size of ~181±5 µm with average depth of ~142± µm were achieved at the optimal range of Va i.e. 28 V to 30 V. Figure 1
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Hammood, Shahad Ali, Haydar Abdul Hassan Al-Ethari, and Abdolreza Rahimi. "Optimization the Machining Parameters of Electro Chemical Discharge Machining of NiTi Shape Memory Alloys." Materials Science Forum 1039 (July 20, 2021): 117–26. http://dx.doi.org/10.4028/www.scientific.net/msf.1039.117.
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The electrochemical discharge machining (ECDM) is a combination effect of electrochemical machining in which metal is removed through the electrochemical process and electrical discharge machining in which metal is removed by rapid current discharges between two electrodes which are separated by a dielectric liquid and subject to an electric voltage. Difficulty of machining nickel titanium alloys by conventional methods such as; the significant tool wear, the need of highly experienced operators, and an excessive degradation in the material performance due to the high thermal and mechanical effects of these methods. For these, reasons non-conventional methods such as electrical discharge machining and electro chemical machining are often used to fabricate NiTi alloys with better machining results. The experiments were conducted with various conditions of voltage (50,60,70 and 80)V, dielectric solution concentration (30 and 40% of NaOH) and nanoparticles silver, and copper content (0.5% Cu, 0.5% Ag, 0.5% Cu and Ag) in the (55% Ni-45%Ti) alloy samples. The machining experiments were designed according to Taguchi's design of experiments (L32). Grey relational analysis was used to optimize the responses of the ECDM process. Material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) represent the response parameters for machining of the alloy samples prepared by the powder metallurgy route. To achieve the objectives of this research work MiniTab17 software was employed. The optimal conditions were: voltage of 50V, solution concentration of 40% and the sample (NiTi+0.5%Cu+0.5%Ag) have the highest effect on machining characteristics with MRR value of 0.04991mg/sec., tool wear rate value of 0.00125mg/sec., and surface roughness of 0.0117μm.
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Yang, C. T., S. S. Ho, and Bo Huei Yan. "Micro Hole Machining of Borosilicate Glass through Electrochemical Discharge Machining (ECDM)." Key Engineering Materials 196 (January 2001): 149–66. http://dx.doi.org/10.4028/www.scientific.net/kem.196.149.
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Tayade, R. M., B. Doloi, B. R. Sarkar, and B. Bhattacharyya. "Micro-Hole Drilling on Ti6Al4V by Sequential Electro-Micro-Machining (SEMM) Approach." Journal of Advanced Manufacturing Systems 19, no. 03 (2020): 499–516. http://dx.doi.org/10.1142/s0219686720500249.
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This research work explores the feasibility of drilling micro-holes on Ti6Al4V by applying a sequential electro-micro-machining process. A novel sequential combination of micro-electrochemical discharge machining ([Formula: see text]ECDM) and micro-electro-chemical machining ([Formula: see text]ECM) is applied for drilling micro-hole in titanium alloy (Ti6Al4V). The machining of titanium alloy by a [Formula: see text]ECDM process is a challenging task and not reported yet. Therefore, the feasibility of machining of Ti6Al4V by [Formula: see text]ECDM using various combinations of electrolytes has been studied. The best-suited electrolyte for drilling by [Formula: see text]ECDM was selected by analyzing the hole depth, radial overcut, hole taper angle and the minimum time required to drill through holes in a 400[Formula: see text][Formula: see text]m thick sheet of titanium alloy. The [Formula: see text]ECDM process produces micro-holes rapidly but it consists of recast layer, micro-cracks, and heat affected zone, etc. The surface characteristics of a [Formula: see text]ECDMed hole were improved by applying [Formula: see text]ECM process subsequent to the [Formula: see text]ECDM process. The sequential combination of [Formula: see text]ECDM shaping and [Formula: see text]ECM finishing results in improved dimensional accuracy, machining depth, taper angle, and surface quality of the hole produced by sequential micro-machining process.
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Singh, Dilpreet, and Mudimallana Goud. "A 3D Spark Model to Evaluate MRR in ECDM." Journal of Advanced Manufacturing Systems 18, no. 03 (2019): 435–46. http://dx.doi.org/10.1142/s0219686719500239.
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Electrochemical discharge machining (ECDM) is an advanced machining process which uses both chemical action and spark discharge method for removal of materials. Till date, most of the applications of ECDM are in machining nonconductive materials, although some authors have also tried machining conductive materials. This paper attempts to develop a finite element simulation model based on heat generation in the spark region to evaluate material removal rate (MRR) in case of quartz and soda lime glass. The calculation of MRR is based on melting and evaporation of the material due to high temperature generated due to spark discharge. Convection heat transfer is also considered in the analysis. The results obtained from the simulation are compared with available experimental results and previous simulation results. Although this process is not used in the industry till now, it has a lot of scope for research and development.
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Nawaz, Shan Ali, Peiyao Cao, Hao Tong, and Yong Li. "Micro ECDM process comparison using different tool feed methods of constant gravity and spring-force." Journal of Physics: Conference Series 2671, no. 1 (2024): 012001. http://dx.doi.org/10.1088/1742-6596/2671/1/012001.
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Abstract 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.
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Aninda, Das, Chandra Chandra Puspendu, and Mukherjee Sabyasachi. "ELECTROCHEMICAL DISCHARGE MACHINING FOR MICRO-CHANNEL CUTTING ON ELECTRICALLY NON-CONDUCTING MATERIAL." International Journal of Advanced Trends in Engineering and Technology 2, no. 2 (2017): 141–52. https://doi.org/10.5281/zenodo.1040910.
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The present research work is based on the detailed experimental observations on the performance characteristics of ECDM set-up during channel cutting operation. The electrochemical discharge machining (ECDM) process have been applied successfully for micro-channel cutting on electrically non-conducting material like glass irrespective of its chemical and mechanical properties and also the tool geometry. It has been found that the MRR and Width are increase with the increase of applied voltage at fixed electrolyte concentration. Also it is observed that the MRR and Width varies with respective to the nature of the tool. The least WOC is observed at applied voltage of 50 V with 15 wt% concentration of NaOH salt solution using curved tool.
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Kumar Gupta, Pankaj, Akshay Dvivedi, and Pradeep Kumar. "Effect of Electrolytes on Quality Characteristics of Glass during ECDM." Key Engineering Materials 658 (July 2015): 141–45. http://dx.doi.org/10.4028/www.scientific.net/kem.658.141.
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Electrochemical discharge machining (ECDM) is an ideal process for machining of nonconductive materials in micro-domain. The material removal takes place due to combined action of localised sparks and electrolysis in an electrolytic chamber. The electrolyte is most important process parameter for ECDM as it governs spark action as well as electrolysis. This article presents a comparison of three preferred electrolytes used in ECDM viz. NaCl, KOH and NaOH on drilling of glass workpiece material. The quality characteristics measured are material removal rate (MRR) and hole overcut. Results reveal that NaOH provides 9.7 and 3.8 times higher MRR than NaCl and KOH respectively. MRR and hole overcut are found significantly affected by spark characteristics.
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Tsui, Hai Ping, Kuang Hua Chang, and Biing Hwa Yan. "Surface Roughening of Silicon Wafer Solar Cell by Using ECDM Method." Key Engineering Materials 825 (October 2019): 62–70. http://dx.doi.org/10.4028/www.scientific.net/kem.825.62.
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This research proposes surface roughening of silicon wafer solar cell by electrochemical discharge machining (ECDM). The stainless steel was used as negative electrode. The graphite was used as the positive electrode acting as the auxiliary electrode. The potassium hydroxide was used as the electrolyte. The processing parameters include the machining voltage, the processing time, the machining gap, the electrolyte concentration, the additive agent concentration, pulse frequency and duty factor, etc. The result of experiments reveals that appropriate concentrations of ethanol can expand the size of the pores and enhance surface roughening effect. The appropriate processing parameters are a machining gap of 200μm, voltage of 48V, concentration of potassium hydroxide of 3M, concentration of ethanol of 4%. The electrochemical discharge machined surface roughness was increased from 0.417μm to 0.915μm using one minute processing time. The average reflectance rate of the textured surface was decreased from 29.6% to 12.7%. This study reveals that ECDM method has the advantage of short processing time and can generate a higher surface roughness and the porous structure.
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Liao, Yunn Shiuan, and Wen Yang Peng. "Study of Hole-Machining on Pyrex Wafer by Electrochemical Discharge Machining (ECDM)." Materials Science Forum 505-507 (January 2006): 1207–12. http://dx.doi.org/10.4028/www.scientific.net/msf.505-507.1207.
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The gap control problem in hole-machining of Pyrex® wafer by electrochemical discharge machining (ECDM) to obtain a smooth quality and acceptable material removal rate is studied. Analysis of the pulse signals shows that the average current pulse interval is constant, and it is mainly related to the ion translation conditions, such as the electrolyte concentration and the flushing strategy. The most steady and intense average current density can be obtained if the voltage on-time is around 3 times the average current pulse interval and the voltage off-time is 1/4 of the on-time for bubble film dissipation. The utmost allowable feed rate at each depth is recorded as the reference of the feed rate in real continuous machining to avoid the damage to the wafer. By applying 80% of the extreme allowable feed rate, 99.9% quality-proved holes can be acquired. The diametric error at the entrance or exit is within 6%. Besides, there is no crater-like problem around the hole that facilitates the succeeding bonding process. This study contributes to the successful production of reusable optical biological chips with integrated micro fluidic channels.
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Ho, Chao-Ching, and Jia-Chang Chen. "Micro-Drilling of Sapphire Using Electro Chemical Discharge Machining." Micromachines 11, no. 4 (2020): 377. http://dx.doi.org/10.3390/mi11040377.
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Electrochemical discharge machining (ECDM) refers to a non-traditional machining method for performing effective material removal on non-conductive hard and brittle materials. To increase the ECDM machining efficiency, traditionally, the method of increasing the machining voltage or increasing the electrolyte concentration is used. These methods can also cause overcut reaming of the drilled holes and a rough surface on the heat affected area. In this study, an innovative combinational machining assisted method was proposed and a self-developed coaxial-jet nozzle was used in order to combine two assisted machining methods, tool electrode rotation and coaxial-jet, simultaneously. Accordingly, the electrolyte of the machining area was maintained at the low liquid level and the electrolyte was renewed at the same time, thereby allowing the spark discharge to be concentrated at the contact surface between the front end of the tool electrode and the machined material. In addition, prior to the machining and micro-drilling, the output of the machining energy assisted mechanism was further controlled and reduced. For the study disclosed in this paper, experiments were conducted to use different voltage parameters to machine sapphire specimens of a 640 μm thickness in KOH electrolyte at a concentration of 5 M.
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Rajput, Viveksheel, Mudimallana Goud, and Narendra Mohan Suri. "Multi-spark simulation of the electrochemical discharge machining (ECDM) process." Journal of Mechanical Science and Technology 35, no. 11 (2021): 5127–35. http://dx.doi.org/10.1007/s12206-021-1029-7.
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Rajput, Viveksheel. "Analyzing the Electrode Feed in Electrochemical Discharge Machining (ECDM) Process." International Journal for Research in Applied Science and Engineering Technology 8, no. 8 (2020): 1256–62. http://dx.doi.org/10.22214/ijraset.2020.31136.
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Mallick, Bijan, Sumit Biswas, Biplab Ranjan Sarkar, Biswanath Doloi, and Bijoy Bhattacharyya. "On Performance of Electrochemical Discharge Micro-Machining Process Using Different Electrolytes and Tool Shapes." International Journal of Manufacturing, Materials, and Mechanical Engineering 10, no. 2 (2020): 49–63. http://dx.doi.org/10.4018/ijmmme.2020040103.
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The electro-chemical discharge micro-machining (µ-ECDM) process can be utilised as a potential micro-machining process, which offers several advantages such as cost-effectiveness and diversity in applications on electrically non-conducting hard brittle materials like glass. The present research article includes the analysis of material removal rate (MRR), width of cut (WOC), heat affected zone (HAZ), and surface roughness (Ra) during µ-channeling on glass with a micro-ECDM process, considering applied voltage (V), electrolyte concentration (wt%), and tool shapes as process parameters. A comparative study is conducted to select the suitable tool shape and electrolyte. Moreover, the optical and SEM images are used to examine HAZ, WOC and topography of µ-channels. MRR and WOC enhance with the rise of applied voltage for fixed electrolyte concentration and vary with tool shape. Surface roughness (Ra) is found low at applied voltage of 55V and 60V for both electrolytes when straight and curved tools, respectively, are used. The straight tool shape is more suitable for µ-channeling on glass by µ-ECDM.
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Pawar, Pravin, Amaresh Kumar, and Raj Ballav. "Parametric Analysis of Electrochemical Discharge Drilling on Soda-Lime Glass Material Using Taguchi L27 Orthogonal Array Method." Strojnícky časopis - Journal of Mechanical Engineering 69, no. 4 (2019): 115–32. http://dx.doi.org/10.2478/scjme-2019-0047.
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AbstractThe Electrochemical discharge machining (ECDM) is a hybrid non-traditional process which is specifically used for machining of conducting as well as non-conducting materials. In this research work, the fabricated ECDM experimental setup was used to machine the Soda-lime glass material with Brass tool material. The experiments were done on Soda-lime glass material with the help of Taguchi L27 orthogonal array method and analysed by using MINITAB 17 software. The average hole diameter and average machined depth results were checked after ECDM drilling on Soda-lime glass material with considering the input process parameters such as an electrolyte concentration, voltage and rotation. The experimental results indicated that voltage was the most dominant factor for average machined depth followed by an electrolyte concentration and rotation speed. The rotation speed was the most dominant factor for average hole diameter followed by voltage and electrolyte concentration.
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Pawar, Pravin, Amaresh Kumar, and Raj Ballav. "Grey Relational Analysis Optimization of Input Parameters for Electrochemical Discharge Drilling of Silicon Carbide by Gunmetal Tool Electrode." Annales de Chimie - Science des Matériaux 44, no. 4 (2020): 239–49. http://dx.doi.org/10.18280/acsm.440402.
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The electrochemical discharge machining process (ECDM) is a hybrid advanced technology integrated with electrochemical and electro-discharge processes has used for the manufacturing of non-conducting along with conducting materials. The silicon carbide is non-conducting material which has widely used in various fields such as automobile, aviation, medical, nuclear reactor, and missile. The machining of silicon carbide is a challenging task by using non-conventional along with conventional machining processes due to its physical properties. The current research work shows the machining of Silicon carbide material by using fabricated ECDM machine setup with gunmetal tool material. The Taguchi L27 orthogonal array technique is applied for experimental work. The grey relational analysis optimization is applied for the investigation of optimum input factors for better output responses. The input process factors like electrolyte concentration, applied voltage, and rotation of tool and outcome results such as machined depth and the diameter of hole were checked after drilling of silicon carbide material. The experimental results indicate the electrolyte concentration is the leading factor for diameter of hole and depth of machined hole subsequent to voltage and tool rotation.
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Nioaţă, Alin, and Florin Ciofu. "Influence Factors Hierarchization in Electrochemical Discharge Machining (ECDM) Using the Random Balance Method." Applied Mechanics and Materials 809-810 (November 2015): 321–26. http://dx.doi.org/10.4028/www.scientific.net/amm.809-810.321.
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In the case of electrochemical discharge machining (ECDM), the number of influence factors is very high, and the complete determination of a mathematic pattern is very complicated, as proved by the time passed since the application of this processing technology and absence (for the time being) of such a system. The paper presents the method of random balance which allows influence factors hierarchization, depending on the amplitude of the effect they have on the response variable. The main influence factors will be considered: current intensity, voltage, electrode-tool – workpiece pressure, electrolyte supply intensity, relative velocity between the electrode-tool and the workpiece, electrode-tool thickness. The following response functions (performance criteria) were determined: processing productivity, processed surface roughness, flatness deviation. The experiment was made on an electrochemical discharge machining (ECDM) processing machine with a electrode-tool, stratified disk by introducing the electrolyte in it. The semi-finished material is alloy steel X40CrMoV5-1, and the material of the electrode-tool is generally use steel S235JR.
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Harugade, Mukund, Sachin Waigaonkar, and Nandkishor Dhawale. "A novel approach for removal of delaminated fibers of a reinforced composites using electrochemical discharge machining." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, no. 12 (2021): 1949–60. http://dx.doi.org/10.1177/09544054211014483.
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Fiber reinforced composites, also referred as fiber reinforced plastics (FRPs) have gained considerable importance in engineering applications due to their unique qualities like high strength and stiffness at lesser weight, chemical inertness, thermal resistance, corrosion resistance, and electrical resistance. Though the machining of FRPs is not recommended, many times it is inevitable and the primary machining process like drilling is essential. This can cause delamination of the fibers thereby adversely affecting the mechanical properties of the composite and requires additional secondary finishing operation. The present investigation explores electrochemical discharge machining (ECDM) as a one of the novel technique to remove the delaminated fibers from such composites. Using ECDM the protruded delaminated fibers from a drilled hole in FRP have been precisely eliminated. Two different approaches viz. top machining and inside machining were followed for this purpose. Process evaluation was done in terms of its ability to remove the delaminated fibers and the extent of thermal damage (heat affected zone and hole overcut) to the workpiece. Both approaches have shown considerable potential of removal of delaminated fibers precisely.
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Mallick, B., B. R. Sarkar, B. Doloi, and B. Bhattacharyya. "Multi Criteria Optimization of Electrochemical Discharge Micro-Machining Process during Micro-Channel Generation on Glass." Applied Mechanics and Materials 592-594 (July 2014): 525–29. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.525.
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Electrochemical Discharge micro-machining process appears better utility with greater effectiveness in the modern micro-machining industrial field. Electrochemical discharge micro-machining process is involved to generate micro-channel as well as curve profile on glass for utilization as micro-fluidic device. This paper shows second order mathematical modeling of correlation between the machining criteria such as machining rate as a form of material removal rate (MRR), overcut (OC), machining depth (MD) with various process parameters like applied voltage (V), electrolyte concentration (wt %) and inter-electrode gap (IEG) (mm). The analysis of variance (ANOVA) has been performed to find out the adequacy of the developed models.This paper also shows the multi objective optimization to achieve the optimal parametric combination for maximum MRR, MD and minimum OC using response surface methodology (RSM). Keywords:μ-ECDM,MRR,OC,MD,RSM,ANOVA,Glass.
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Bahar, Dil, Akshay Dvivedi, and Pradeep Kumar. "Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature." Journal of Micromechanics and Microengineering 34, no. 3 (2024): 035001. http://dx.doi.org/10.1088/1361-6439/ad2089.
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Abstract 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.
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Rajput, Viveksheel, Mudimallana Goud, and Narendra Mohan Suri. "Finite Element Modeling for Analyzing Material Removal Rate in ECDM Process." Journal of Advanced Manufacturing Systems 19, no. 04 (2020): 815–35. http://dx.doi.org/10.1142/s0219686720500365.
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Electrochemical discharge machining (ECDM) has been developed as a hybrid and robust technology for machining non-conductive work material at a preferable removal rate. ECDM exhibits various applications in the micro-machining of these materials like nuclear, automotive, medical industries, etc. Due to some peculiar properties of nonconductive materials, for example, glass transparency, their utilization in MEMS applications are also very numerous. In the ECDM process, removal of material takes place primarily due to high-temperature thermal erosion and secondarily due to electrolyte chemical etching action. Many rigorous experimental studies have reported in the empirical estimation of the material removal rate (MRR) in the ECDM process. However, very few studies have reported in the modeling of the ECDM process for predicting material removal rate through single spark simulation. The present paper attempts to develop a transient thermal model based upon finite element modeling (FEM) to simulate a single spark in the ECDM process for obtaining temperature fields in the work material. The obtained temperature fields are further post-processed to predict the material removal rate. FEM results are compared with the previous simulated and experimental results to confirm the approach. Moreover, an experimental study is also performed to validate the developed thermal model and it was found to be in an acceptable range of the experimental results. Further, a parametric study revealed that MRR increases with the increase in applied voltage and electrolyte concentration during soda-lime glass machining with ECDM. The developed FEM-based transient thermal model can be successfully utilized for predicting the removal rate of nonconductive work material.
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Tang, Lin, and Gang Gang Zhao. "Discussing the Measure of Improving Pyrex Glass ECDM Removal Rate." Advanced Materials Research 411 (November 2011): 319–22. http://dx.doi.org/10.4028/www.scientific.net/amr.411.319.
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Electrochemical discharges machining (ECDM) is an unconventional technology able to machine several non-conductive materials like glass or some ceramics. ECDM technology remains an academic application and was never applied in industrial. The limit factors are highlighted. In order to improve removal rate (MRR) of Pyrex glass ECDM material and the surface quality, many promising measures such as ultrasonic vibration, abrasive, and side-insulated electrode are discussed.
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Jui, Sumit K., Abishek B. Kamaraj, and Murali M. Sundaram. "High aspect ratio micromachining of glass by electrochemical discharge machining (ECDM)." Journal of Manufacturing Processes 15, no. 4 (2013): 460–66. http://dx.doi.org/10.1016/j.jmapro.2013.05.006.
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Sarkar, B. R., B. Doloi, and B. Bhattacharyya. "Investigation on Electrochemical Discharge Micro-Machining of Silicon Carbide." International Journal of Materials Forming and Machining Processes 4, no. 2 (2017): 29–44. http://dx.doi.org/10.4018/ijmfmp.2017070103.
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Electrochemical discharge machining (ECDM) process has great potential to machine hard, brittle and electrically non-conducting materials in micron range. The objective of this paper is to investigate into electrochemical discharge micro-machining on electrically semi-conductor type silicon carbide (SiC) material so as to study the effects of applied voltage, electrolyte concentration and inter-electrode gap on material removal rate (MRR) and radial overcut (ROC) of micro-drilled hole. Experiments were conducted based on L9 array of Taguchi method with stainless steel µ-tool of 300µm diameter using NaOH electrolyte. An attempt has been made to find out the single as well as multi-objective optimal parametric combinations for maximum MRR and minimum ROC. The single-objective parametric combinations were selected as 45V/20wt%/20mm and 25V/20wt%/40mm for maximum MRR and minimum ROC respectively whereas multi-objective optimal parametric combinations was found as 25V/20wt%/40mm. Further mathematical models have been developed between the above machining parameters and characteristics.
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Yadav, Santosh Kumar, Abhishek Singh, and Kishore Debnath. "Analysis of Mass Concentration and Morphology of Fume Particles during ECDM of CFRP Composites." Materials Science Forum 1073 (October 31, 2022): 29–35. http://dx.doi.org/10.4028/p-qgdi4t.
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Electrochemical discharge machining (ECDM) is a hybrid method used to generate micro-features in hard and brittle materials (glass, ceramics, and composites) in aerospace, microelectromechanical systems (MEMS), and microfluidic applications. A significant improvement was observed in ECDM process but the effect of the process on the health of working operator are rarely investigated. Sustainability in manufacturing is a major concern for a better environment and safety of human operators. In this paper, analysis of fumes mass concentration (FMC), size and morphology of fume particles, and composition of fume particles along with their biological effects are studied during ECDM of CFRP composites. FMC was calculated by varying the concentration of electrolyte from 20 to 50% and duty cycle from 60 to 90% for a fixed sampling duration of 30 minutes. SEM images indicated the presence of spherical, irregular, and loosely packed fumes particles in the fumes generated during machining. EDS was also performed to study the chemical composition of fumes particles.
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Hourng, L. W., C. I. Lin, and B. G. Lee. "The Improvement of Machining Accuracy on Quartz and Glasses by Electrochemical Discharge Machining." Applied Mechanics and Materials 472 (January 2014): 682–87. http://dx.doi.org/10.4028/www.scientific.net/amm.472.682.
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In the present study, a tungsten rod with diameter of 100μm is used as the tool to drill a quartz plate by Electrochemical Discharge Machining (ECDM). KOH solution mixed with different concentration of Ethanol is used as the electrolyte. The influences of different working parameters, such as electrolyte concentration, applied voltage, pulse frequency, and electrolyte level, on the gas film stability, gas film thickness, and machining accuracy are investigated. The experimental results show that the overcut and surface roughness is improved by the use of electrolyte with addition of 6.5wt% ethanol. The effect of gaseous bubbles is reduced during the machining, and the circulation of electrolyte is better. Compared with machining with pure KOH electrolyte, the overcut is reduced around 57% by the use of electrolyte with addition of 6.5wt% ethanol. The heat-effected zone on the machining is also largely reduced.
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Sambathkumar, Saranya, and Ravi Sankar Arunagirinathan. "A Simple Technique for the Precise Establishment of the Working Gap in an Electrochemical Discharge Machining Process and Some Experimental Results Thereof." Micromachines 13, no. 9 (2022): 1367. http://dx.doi.org/10.3390/mi13091367.
Full textAbstract:
The working gap (Wg) between a tooltip and a substrate surface is a critical process parameter affecting the quality metrics and precision of microstructures fabricated using an electrochemical discharge machining (ECDM) process. Despite the extensive investigation carried out on ECDM processes for the last several years, only a few researchers have explicitly explained the technique used to establish the Wg. In the present work, the authors propose a simple, cost-effective technique using a commercially available metallic feeler gauge and a multimeter to precisely establish a Wg in an ECDM process. A systematic experimental investigation was carried out using the proposed method to study the influence of Wg on the quality metrics such as the depth, width, edge linearity, heat-affected zone, and surface finish of fabricated microstructures on a glass substrate. Experimental results revealed that even a 2 µm difference in Wg significantly influenced the quality and quantity metrics of an ECDM process. It was observed that no machining occurred beyond a Wg of 25 µm even when a TTR as low as 0.5 mm/min and an applied voltage greater than 44 V were used. A micro-channel with improved quality metrics was obtained using a tool travel rate (TTR) of 1 mm/min with an applied voltage of 33 V and a Wg of 2 µm while using 30% NaOH as an electrolyte. The proposed method would be helpful for researchers to fabricate precise micro-channels on glass substrates using ECDM processes.
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Bian, Jianxiao, Baoji Ma, Xiaofeng Liu, and Lijun Qi. "Experimental Study of Tool Wear in Electrochemical Discharge Machining." Applied Sciences 10, no. 15 (2020): 5039. http://dx.doi.org/10.3390/app10155039.
Full textAbstract:
Electrochemical discharge machining (ECDM) is an emerging special processing technology for non-conductive hard and brittle materials, but it may encounter the problem of tool wear due to its process characteristics, which affects the processing accuracy. In this study, in the non-machining state, the tungsten carbide spiral cathode with a diameter of 400 μm was selected to analyze the influencing mechanism of the process parameters on tool wear, and a suitable voltage range for the processing was obtained. The influence of the cathode’s loss behavior on the film formation time and the average current of spark discharge was discussed based on the current signal. The results show that the tool wear mainly appears from the bottom to the end and edge tip of the protrusion. Loss is mainly in the form of local material melting or gasification at high temperature. In addition, the loss may shorten the film formation time, but the effect on the average current of spark discharge is small.