Effect of Electrolytes on Quality Characteristics of Glass during ECDM

Article Preview

Abstract:

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.

You might also be interested in these eBooks

Info:

Periodical:

Pages:

141-145

Citation:

Online since:

July 2015

Export:

Price:

* - Corresponding Author

[1] H. Kurafuji, K. Suda, Electrical discharge drilling of glass, Annals of the CIRP. 16 (1968) 415-418.

Google Scholar

[2] M. Kubota and Tamura, ECDM drills a steel plate with high feed rate, Bulletin of the Japan Society of Precision Engineering. 7 (1973) 117.

Google Scholar

[3] V.K. Jain, P.M. Dixit and P.M. Pandey, On the analysis of electrochemical spark machining process, Int J Mach Tools and Manuf. 39 (1999) 165-189.

Google Scholar

[4] H. Langen, J.M. Breguet, H. Bleuler, Ph. Renaud, Masuzawa, Micro electrochemical discharge machining of glass, International Journal of Electrical Machining. 3 (1998) 65-69.

DOI: 10.2526/ijem.3.65

Google Scholar

[5] R. Wuthrich, Micromachining using electrochemical discharge phenomenon: fundamentals and applications of spark assisted chemical engraving, first ed., William Andrew, Norwich (2009).

Google Scholar

[6] R. Wuthrich and L.A. Hof, The gas film in spark assisted chemical engraving (SACE)—a key element for micro-machining applications, Int. J. Machine Tools and Manuf. 46 (2006) 828–35.

DOI: 10.1016/j.ijmachtools.2005.07.029

Google Scholar

[7] C.T. Yang, S.S. Ho, B.H. Yan, Micro hole machining of borosilicate glass through electrochemical discharge machining (ECDM), Key Eng Mater. 196 (2001) 149–166.

DOI: 10.4028/www.scientific.net/kem.196.149

Google Scholar

[8] R. Wuthrich, V. Fascio, Machining of non-conductive materials using electrochemical discharge phenomenon—an overview, Int J Mach Tools and Manuf. 45 (2005) 1095–1108.

DOI: 10.1016/j.ijmachtools.2004.11.011

Google Scholar

[9] V. Fascio, R. Wuthrich, H. Bleuler, Spark assisted chemical engraving in the light of electrochemistry, Electrochim Acta. 49 (2004) 3997–4003.

DOI: 10.1016/j.electacta.2003.12.062

Google Scholar

[10] M Jalali, P Maillard, R Wuthrich, Towards a better understanding of glass gravity-feed micro-hole drilling with electrochemical discharges, Journal Micromech Microeng. 19 (2001) 045001.

DOI: 10.1088/0960-1317/19/4/045001

Google Scholar

[11] D. Jana, A. Ziki, R. Wuthrich, Tool wear and tool thermal expansion during micro-machining by spark assisted chemical engraving, Int J of Adv Manuf Technol. 61 (2012) 481–486.

DOI: 10.1007/s00170-011-3731-6

Google Scholar

[12] C.P. Cheng, K.L. Wu, C.C. Mai, C.K. Yang, Y.S. Hsu, B.H. Yan, Study of gas film quality in electrochemical discharge machining, Int. J. Machine Tools and Manuf. 50 (2010) 689-697.

DOI: 10.1016/j.ijmachtools.2010.04.012

Google Scholar

[13] J. West, A. Jadhav, ECDM methods for fluidic interfacing through thin glass substrates and the formation of spherical micro cavities, J Micromech Microeng. 17 (2007) 403-409.

DOI: 10.1088/0960-1317/17/2/028

Google Scholar

[14] S.K. Chak and P.V. Rao, The drilling of Al2O3 using a pulsed DC supply with a rotary abrasive electrode by the electrochemical discharge process" Int J Adv Manuf Technol. 39 (2008) 633-641.

DOI: 10.1007/s00170-007-1263-x

Google Scholar

[15] X.D. Cao, B.H. Kim, C.N. Chua, Micro-structuring of glass with features less than 100µm by electrochemical discharge machining, Precision Engineering. 33 (2009) 459–465.

DOI: 10.1016/j.precisioneng.2009.01.001

Google Scholar