Skip to main content
Disciplines
Automotive Business IT + Informatics Construction + Real Estate Electrical Engineering + Electronics Energy + Sustainability Insurance + Risk Finance + Banking Management + Leadership Marketing + Sales Mechanical Engineering + Materials
Events
DE
EN
Books
Journals
Topic Page
Marketing
Start single access now
Access for companies
EXTENDED SEARCH
Log in
Top
Published in:
Non-traditional Micromachining Processes: Opportunities and Challenges Read chapter Read first chapter

2017 | OriginalPaper | Chapter

10. Electrochemical Discharge Micro-machining of Engineering Materials

Authors : B. R. Sarkar, B. Doloi, B. Bhattacharyya

Published in: Non-traditional Micromachining Processes

Publisher: Springer International Publishing

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Electrochemical discharge micro-machining (micro-ECDM) process appears to be very promising as a future micro-machining technique, since in many areas of applications it offers several advantages, which include machining of variety of electrically non-conducting hard, brittle materials including glass, ceramics and composites etc. It is an advanced hybrid micro-machining process that combines the techniques of electrochemical machining (ECM) and electrodischarge machining (EDM). This book chapter focuses on the current researches and developments in micro-ECDM process. The chapter discusses in details about the micro-ECDM system, which includes the mechanical hardware unit, electrolyte supply unit and electrical power supply unit etc. The effects of various factors on different machining performance characteristics such as material removal rate, accuracy, heat affected zone, gas film quality, machining depth, surface topography and tool wear etc. during its application mainly for micro-drilling and micro-cutting operations on engineering materials are represented in this chapter. The chapter also gives a glimpse on the fundamentals, problematic areas and applications of micro-ECDM process and highlights the challenges and future possibilities of research in this area. The recent advancements for improvement of performance of µ-ECDM process by using the rotating and travelling micro-tool, controlling the gap between the tool and the workpiece, changing the shape of micro-tool and also controlling the surface texture and material of tool for micro-spark discharge for required micro-machining operations are also depicted in this chapter. The chapter is expected to open up new insights into the process characteristics for successful application of electrochemical discharge micro-machining (micro-ECDM) process and provides valuable guidance to the applied researchers and manufacturing scientists for setting up unique platform for micro-machining electrically non-conducting engineering materials.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

inform now
previous chapter Electrochemical Micromachining of Titanium and Its Alloys
next chapter Travelling Wire Electrochemical Spark Machining: An Overview
Literature
1.
I. Basak, and A. Ghosh, Mechanism of spark generation during electrochemical-discharge machining-A theoretical model and experimental verification, Journal of Materials Processing Technology, 62 (1996) 46–53.
2.
A. Kulkarni, R. Sharan, and G. K Lal, An experimental study of discharge mechanism in electro-chemical discharge machining. International Journal of Machine Tools & Manufacture. 42 (2002) 1121–1127.
3.
B. Bhattacharyya, B. N. Doloi, and S. K. Sorkhel., Experimental investigations into electro-chemical discharge machining (ECDM) of non-conductive ceramic materials, Journal  of Materials Processing Technology, 95 (1999) 145–154.
4.
V.K. Jain, P.M. Dixit, and P.M. Pandey, On the analysis of the electrochemical spark machining process, International Journal of Machine Tools and Manufacture, 39 (1999) 165–186.
5.
V.K. Jain, P.S. Rao, S.K. Choudhury, K.P. Rajurkar, Experimental investigations into travelling wire electrochemical spark machining (TW-ECSM) of composites, Transactions of ASME, Journal of Engineering for Industry, 113 (1991) 75–84.
6.
R. Wüthrich, and V. Fascio, Machining of non-conducting materials using electro-chemical discharge phenomenon—an overview, International Journal of Machine Tools & Manufacture, 45 (2005) 1095–1108.
7.
B. R. Sarkar, B. Doloi, and B. Bhattacharyya, Parametric analysis on electrochemical discharge machining of silicon nitride ceramics, International Journal of Advanced Manufacturing Technology, 28 (2006) 827–881.
8.
B. R. Sarkar, B. Doloi, and B. Bhattacharyya, Experimental investigation into electrochemical discharge micro-drilling on advanced ceramics, International Journal Manufacturing Technology and Management, 13 (2/3/4) (2008) 214–225.
9.
B. R. Sarkar, B. Doloi, and B. Bhattacharyya, Analysis on the machining characteristics of electrochemical discharge micro-drilling process, 1st and 22nd AIMTDR, IIT Roorkee, (2006), pp 893–898.
10.
W.Y. Peng and Y.S. Liao, Study of ECDM for slicing nonconductive brittle materials, Journal of Materials Processing Technology, 149 (2004), 363–369.
11.
A. Manna, and V. Narang, A study on micromachining of e-glass fibre–epoxy composite by ECSM process, International Journal of Advanced Manufacturing Technology, 61 (2012) 1191–1197.
12.
X. D. Cao, B. H. Kim, and C. N. Chu, Micro-structuring of glass with features less than 100 μm by electrochemical discharge machining, Precision Engineering, 33 (2009) 459–465.
13.
Z-P. Zheng, W-H. Cheng, F-Y. Huang, and B-H. Yan, 3D micro structuring of Pyrex glass using the electrochemical discharge machining process, Journal of Micromechanics & Microengineering, 17 (2007) 960–966.
14.
E.S. Lee, D. Howard, E. Liang S. D. Collins and R. L. Smith, Removal of tubing interconnects for glass-based micro-fluidic systems made using ECDM, Journal of Micromechanics & Microengineering, 14 (2004), 535–541.
15.
J. West, and A. Jadhav, ECDM methods for fluidic interfacing through thin glass substrates and the formation of spherical microcavities, Journal of Micromechanics & Microengineering, 17 (2007) 403–409.
16.
R Wüthrich, K Fujisaki, Ph Couthy, L A Hof and H Bleuler, Spark assisted chemical engraving (SACE) in micro factory Journal of Micromechanics & Microengineering, 15 (2005) S276–S280.
17.
R. Wüthrich, and L. A. Hof, The gas film in spark assisted chemical engraving (SACE)—A key element for micro-machining applications, International Journal of Machine Tools & Manufacture, 46 (2006) 828–835.
18.
M.S. Han, B.K. Min, and S.J. Lee, Improvement of surface integrity of electro-chemical discharge machining process using powder-mixed electrolyte, Journal of Materials Processing Technology,191 (2007) 224–227.
19.
C.P. Cheng, K.L. Wu, C.C. Mai, Y.S. Hsu, and B.H. Yan, Study of gas film quality in electro-chemical discharge machining, International Journal of Machine Tools & Manufacture, 50 (2010) 689–697.
20.
M.S. Han, B.K. Min, and S.J. Lee, Geometric improvement of electrochemical discharge micro-drilling using an ultrasonic vibrated electrolyte, Journal of Micromechanics & Microengineering, 19 (2009) 8.
21.
R. Wüthrich, L. A. Hof, H. Lal, K. Kujisaki, H. Bleuler, P. Mandin, and G. Picard, Physical principle and minituarisation of spark assisted chemical engraving (SACE), Journal of Micromechanics & Microengineering, 15 (2007) S286–S275.
22.
B. R. Sarkar, B. Doloi, and B. Bhattacharyya, Investigation into the influences of the power circuit on the micro-electrochemical discharge machining process, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 223 (2) (2009), 133–144.
23.
D. J. Kim, Y. Ahn, S. H. Lee, and Y. K. Kim, Voltage pulse frequency and duty ratio effects in an electro-chemical discharge micro-drilling process of Pyrex glass, International Journal of Machine Tools & Manufacture, 46 (2006) 1064–1067.
24.
R. Wuthrich, B. Despont, P. Maillard, and H. Bleuler, Improving the material removal rate in spark-assisted chemical engraving (SACE) gravity-feed microhole drilling by tool vibration, Journal of Micromechanics & Microengineering, 16 (2006) N28–N31.
25.
M. Jalali, P. Maillard, and R. Wuthrich, Toward abetter understanding of glass gravity-feed micro-hole drilling with electrochemical discharges, Journal of Micromechanics & Microengineering, 19 (2009) 045001 (7 pp).
26.
C. K. Yang, K. L. Wu, J. C. Hung, S. M. Lee, J. C. Lin, and B. H. Yan, Enhancement of ECDM efficiency and accuracy by spherical tool electrode, International Journal of Machine Tools & Manufacture, 51 (2011) 528–535.
27.
C. K. Yang, C. P. Cheng, C. C. Mai, A. C. Wang, J. C. Hung, and B. H. Yan, Effect of surface roughness of tool electrode materials in ECDM performance, International Journal of Machine Tools & Manufacture, 50 (2010) 1088–1096.
28.
P. Maillard, B. Despont, H. Bleuler, and R. Wüthrich, Geometrical characterization of micro-holes drilled in glass by gravity-feed with spark assisted chemical engraving (SACE), Journal of Micromechanics & Microengineering, 17 (2007) 1343–9.
29.
C. T. Yang, S. L. Song, B. H. Yan, and F. Y. Huang, Improving machining performance of wire electro-chemical discharge machining by adding SiC abrasive to electrolyte, International Journal of Machine Tools & Manufacture, 46 (2006) 2044–2050.
30.
C.P. Cheng, K.L. Wu, C.C. Mai, Y.S. Hsu, and B.H. Yan, Magnetic field-assisted electrochemical discharge machining, Journal of Micromechanics & Microengineering, 20 (2010) 7.
31.
T.F. Didar, A. Dolatabadi, and R. Wüthrich, Characterization and modelling of 2D- glass micro-machining by spark-assisted chemical engraving (SACE) with constant velocity, Journal of Micromechanics & Microengineering, 18 (2008) 9.
32.
B.K. Bhuiyan, and V. Yadava, Experimental study of traveling wire electrochemical spark machining of borosilicate glass, Materials and Manufacturing Processes, 29 (2014) 298–304.
33.
K.Y. Kuo, K.L. Wu, C.K. Yang, and B.H. Yan, Wire electrochemical discharge machining (WECDM) of quartz glass with titrated electrolyte flow, International Journal of Machine Tools & Manufacture, 72 (2013) 50–57.
34.
D. Jana, A. Ziki, T.F. Didar, and R. Wüthrich, Micro-texturing channel surfaces on glass with spark assisted chemical engraving, International Journal of Machine Tools & Manufacture, 57 (2012) 66–72.
35.
L. Paul, and S.S. Hiremath, Characterisation of micro-channels in electrochemical discharge machining process, Applied Mechanics and Materials,  490–491 (2014) 238–242.
36.
T. Singh, and A. Dvivedi, Developments in electrochemical discharge machining: A review on electrochemical discharge machining, process variants and their hybrid methods, International Journal of Machine Tools & Manufacture, 105 (2016) 1–13.
Metadata
Title
Electrochemical Discharge Micro-machining of Engineering Materials
Authors
B. R. Sarkar
B. Doloi
B. Bhattacharyya
Copyright Year
2017
Book
Non-traditional Micromachining Processes

Print ISBN: 978-3-319-52008-7

Electronic ISBN: 978-3-319-52009-4

Copyright Year: 2017

DOI
https://doi.org/10.1007/978-3-319-52009-4_10

Premium Partners

    Image Credits