Study on the characteristics of magnetic field-assisted electrochemical microvia deburring

The electrochemical deburring (ECD) process has large stray corrosion and other problems, resulting in the degradation of the machined surface quality. Therefore, a magnetic field is added to improve the processing effect of ECD. This paper studies the machining characteristics of magnetic field-assisted electrochemical deburring (MD-ECD) and determines the optimized machining effect. Firstly, a three-field coupled simulation model of magnetic field, electric field and flow field for MD-ECD was established to analyze the influence of magnetic field on electrolyte flow. Secondly, simulation experiments were conducted on the influence of magnetic fields on electrolyte flow, studying the effects of transverse magnetic fields (TMF) and longitudinal magnetic fields (LMF) on the flow of MD-ECD electrolyte. Finally, a microvia burr removal experiment with a diameter of 800 μm was conducted to verify the correctness of the simulation, and the flow of the bubble layer and its impact on burr removal were analyzed. The results indicate that during the MD-ECD machining process, the electrolyte circulates and flows, and the magnetic field strength is positively correlated with the electrolyte flow rate. The placement of the magnetic field has a significant impact on the flow of electrolyte, especially the circulation flow effect of LMF processing method is better. Compared with no magnetic field (NMF) processing, when the magnetic field strength is 0.2 T, the stray corrosion area is reduced by about 50%, the chamfer depth is reduced by more than 40%, and the degree of hole expansion is reduced by more than 50%.