Abstract
The electrochemical micromachining (ECMM) system is a modern equipment well thought out as the phenomenon of conventional electrochemical machining (ECM) system in microscale. The ECM system and ECMM system are similar, but the practice method and mechanism involved in the ECM system are analogous to those of the ECMM system, i.e., the differences in machining conditions and machining performance give rise to a factor called the scale effect. In this paper, ECMM has been applied with the advantageous concept called scale effect. Single factor experiments are conducted in which voltage, duty ratio, and tool feed rate are considered as the input factors for the exploration of the different grades of scale effect through the material removal rate, circularity, and overcut. The scale effects that occurred during machining are found using the similarity precision of the micro- and macrosystems based on the similarity theory. Quantitative evaluation of the scale effects is done for the ECMM process. The evaluation showed greater similarity precision indicating a larger significant scale effect. The output values of MRR, circularity, and overcut were normalized which also showed a positive scale effect. The research on scale effects delivers benefits in engineering such as optimizing the processing parameters involved and improving the machining performances of ECMM.
Similar content being viewed by others
Abbreviations
- ECM:
-
Electrochemical machining
- ECMM:
-
Electrochemical micromachining
- EDM:
-
Electrical discharge machining
- CPE:
-
Composite electrolyte
- MRR:
-
Material removal rate
- IEG:
-
Interelectrode gap
- VMS:
-
Video measuring system
- EDL:
-
Electrical double layer
References
Vaidya S, Ambad P, Bhosle S (2018) Industry 4.0 – a glimpse 2nd International Conference on Materials Manufacturing and Design Engineering. Procedia Manuf 20:233–238. https://doi.org/10.1016/j.promfg.2018.02.034
Wilson JF (1971) Practice and theory of electrochemical machining. Wiley, New York
Gusseff W (1929) Electrochemical machining of metals. British Patent No 335 003
De Barr AE, Oliver DA (1968) Electrochemical machining. Macdonald and Co Ltd, London
Trimmer AL, Hudson JL, Kock M, Schuster R (2003) Single-step electrochemical machining of complex nanostructures with ultrashort voltage pulses. Appl Phys Lett 82(19):3327–3329
Klocke F, Harst S, Zeis M, Klink A (2016) Energetic analysis of the anodic double layer during electrochemical machining of 42CrMo4 steel. Procedia CIRP 42:396–401
Ahn SH, Ryu SH, Choi DK, Chu CN (2004) Electro-chemical micro drilling using ultra short pulses. Precis Eng 28:129–134
Bannard J (1977) Effect of flow on the dissolution efficiency of mild steel during ECM. J Appl Electrochem 7:267–270
Tang L, Li B, Yang S, Kang B (2014) The effect of electrolyte current density on the electrochemical machining S-03 material. Int J Adv Manuf Technol 71:1825–1833. https://doi.org/10.1007/s00170-014-5617-x
Qu NS, Fang XL, Zhang YD, Zhu D (2013) Enhancement of surface roughness in electrochemical machining of Ti6Al4V by pulsating electrolyte. Int J Adv Manuf Technol 69:2703–2709. https://doi.org/10.1007/s00170-013-5238-9
Kellock B (1982) Journal of Machinery and Production Engineering 140(3604):40
Mileham AR, Harvey SJ, Stout KJ (1986) The characterization of electrochemically machined surfaces. J Wear 109(207): 207–214. https://doi.org/10.1016/0043-1648(86)90265-6
McGeough J (1963) Principles of electrochemical machining. Chapman And Hall Ltd/Wiley and Sons, London/New York
Joshi SS, Marla D (2014) Electrochemical micromachining A2 - Hashmi, Saleem. In: Batalha GF, Tyne CJV, Yilbas B (eds) Comprehensive materials processing. Elsevier, Oxford, pp 373–403
Zhan D, Han L, Zhang J, Shi K, Zhou J-Z, Tian Z-W, Tian Z-Q. Confined chemical etching for electrochemical machining with nanoscale accuracy. Acc Chem Res special issue “Nano electrochemistry”. https://doi.org/10.1021/acs.accounts.6b00336
Rajurkar KP, Zhu D, Wei B (1998) Minimization of machining allowance in electrochemical machining. CIRP Ann Manuf Technol 47:165–168
Tenigyohi N (1983) Current status in and future trends of ultra-precision machining and ultra-fine material processing. Ann CIRP 2(2):573–582
Datta M, Lubomyr TR (1989) Application of chemical and electro-chemical micro-machining in the electronic industry. J Electrochem Soc 136(6):285–291
Bhattacharyya B, Mitra S, Boro AK (2002) Electrochemical machining: new possibilities for micromachining. Robot Comput Integr Manuf 18:283–289
McGeough JA (1974) Principle of electrochemical machining. Chapman & Hall, London
Sundaram MM, Rajurkar K (2010) Electrical and electrochemical processes, intelligent energy field manufacturing. CRC Press, pp 173–212
Pletcher D (2009) A first course in electrode processes, 2nd edn. The Royal Society of Chemistry, Cambridge
Wolters H-H (2010) Electrochemical machining: SIG material analysis. ECM Technologies, Leeuwarden
Trethewey KR, Chamberlain J (1995) Corrosion for science and engineering, 2nd edn. Longman Group Limited, New York
Bhattacharyya B, Malapati M, Munda J (2005) Experimental study on electrochemical micromachining. J Mater Process Technol 169(3):485–492
Munda J, Malapati M, Bhattacharyya B (2007) Control of microspark and stray-current effect during EMM process. J Mater Process Technol 194(1–3):151–158
Sen M, Shan HS (2005) A review of electrochemical macro- to micro-hole drilling processes. Int J Mach Tool Manu 45(2):137–152
Rajurkar KP, Zhu D, McGeough JA, Kozak J, De Silva A (1999) New developments in electrochemical machining. CIRP Ann 48(2):567–579
Datta M, Shenoy RV, Rominkiw LT (1996) Recent Advances in the study of electrochemical micromachining. ASME. J Eng Ind 118(1):9–36. https://doi.org/10.1115/1.2803644
Van Osenbrugger C, de Regt C (1985) Electrochemical micro machining. Philips Tech Rev 42:22–32
Datta M, Romankiw LT (1989) Applications of chemical and electrochemical micro machining in the electronic industry. J Electrochem Soc 136:285c
Bhattacharyya B, Munda J (2003) Experimental investigation into electrochemical micro machining (EMM) process. Int J Mater Process Technol 140:287–291
Liu Y, Zhu D, Zeng Y, Yu H (2011) Development of microelectrodes for electrochemical micromachining. Int J Adv Manuf Technol 55:195–203. https://doi.org/10.1007/s00170-010-3035-2
Moon Y, Lee E, Park J (2002) A study on electrochemical micromachining for fabrication of microgrooves in an air-lubricated hydrodynamic bearing. Int J Adv Manuf Technol 20:720–726. https://doi.org/10.1007/s001700200229
He B, Chen W, Jane Wang Q (2008) Surface texture effect on friction of a micro textured poly (dimethyl siloxane) (PDMS). Tribol Lett 31:187–197. https://doi.org/10.1007/s11249-008-9351-0
Zhou X, Qu N, Hou Z, Zhao G (2017) Electrochemical micromachining of microgroove arrays on phosphor bronze surface for improving the tribological performance. Chin J Aeronaut 31:1609–1618. https://doi.org/10.1016/j.cja.2017.12.007
Schuster R, Kirchner V, Allongue P, Ertl G (2000) Electrochemical micromachining. Science 289(5476):98–101. https://doi.org/10.1126/science.289.5476.98
Kim BH, Ryu SH, Choi DK (2005) Micro electrochemical milling. J Micromech Microeng 15(1):124–129
Kim BH, Na CW, Lee YS, Choi DK, Chu CN (2005) Micro electrochemical machining of 3D micro structure using dilute sulfuric acid. CIRP Ann Manuf Technol 54(1):191–194
Bhattacharyya B, Munda J, Malapati M (2004) Advancement in electrochemical micro-machining. Int J Mach Tool Manu 44(15):1577–1589
Yong L, Zhu D, Yongbin Z, Shaofu H, Yu H (2010) Experimental investigation on complex structures machining by electrochemical micromachining technology. Chin J Aeronaut 23(578–584):578–584. https://doi.org/10.1016/S1000-9361(09)60257-0
Chen C, Li J, Zhan S, Yu Z, Xu W (2016) Study of micro groove machining by micro ECM. 18th CIRP Conference on Electro Physical and Chemical Machining. Procedia CIRP 42:418–422. https://doi.org/10.1016/j.procir.2016.02.224
Hyoung Ryu S (2009) Micro fabrication by electrochemical process in citric acid electrolyte. J Mater Process Technol 209:2831–2837
Mouliprasanth B, Hariharan P (2019) Measurement of performance and geometrical features in electrochemical micromachining of SS304 alloy. Exp Tech 44:259–273. https://doi.org/10.1007/s40799-019-00350-y
Yong L, Ruiqin H (2013) Micro electrochemical machining for tapered holes of fuel jet nozzles. Micro Electrochemical machining for tapered holes of fuel jet nozzles. Procedia CIRP 6:395–400. https://doi.org/10.1016/j.procir.2013.03.085
Lim YM, Kim SH (2001) An electrochemical fabrication method for extremely thin cylindrical micro pin. Int J Mach Tool Manu 41(15):2287–2296
Jain VK (ed) (2013) Micro manufacturing processes. CRC Press, Boca Raton
Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46(313–332):313–332
Liu Q, Zhang Q, Wang K. Zhu FUX, Zhang J (2016) Scale effects and a method for similarity evaluation in micro electrical discharge machining. Chin. J Mech Eng 29:1193–1199. https://doi.org/10.3901/CJME.2016.0622.077
Dornfeld D, Min S, Takeuchi Y (2006) Recent advances in mechanical micromachining. Ann CIRP 55(2):745–768
Liu X, Devor RE, Kapoor SG, Ehmann KF (2004) The mechanics of machining at the microscale: assessment of the current state of the science. ASME J Manuf Sci Eng 126(4):666–678. https://doi.org/10.1115/1.1813469
Vollertsen F, Biermann D, Hansen HN, Jawahir IS, Kuzman K (2009) Size effects in manufacturing of metallic components. Ann CIRP 58(2):566–587
Geißdörfer S, Engel U, Geiger M (2006) FE-simulation of micro forming processes applying a mesoscopic model. Int J Mach Tool Manu 46(11):1222–1226
Keller C, Hug E (2008) Hall–Petch behaviour of Ni poly crystals with a few grains per thickness. Mater Lett 62(10):1718–1720
Gil Sevillano J, Ocana Arizcorreta I, Kubin LP (2001) Intrinsic size effects in plasticity by dislocation glide. Mater Sci Eng A 309:393–405
Kals TA, Eckstein R (2000) Miniaturization in sheet metal working. J Mater Process Technol 103(1):95–101
Peng L, Liu F, Ni J, Lai X (2007) Size effects in thin sheet metal forming and its elastic–plastic constitutive model. Mater Des 28(5):1731–1736
Simoneau AE, Elbestawi MA (2006) Surface defects during micro cutting. Int J Mach Tool Manu 46(12):1378–1387
Kim JD, Kim DS (1995) Theoretical analysis of micro-cutting characteristics in ultra-precision machining. J Mater Process Technol 49(3):387–398
Wang K, Zhang Q, Zhang J (2019) Evaluation of scale effect of micro electrical discharge machining system. J Manuf Process 38(174–178):174–178
Liu Q, Zhang Q, Zhang M, Zhang J (2016) Review of size effects in micro electrical discharge machining. Precis Eng 44(29–40):29–40
Kozak J (2004) Thermal models of pulse electrochemical machining. Bull Pol Acad Sci Tech Sci 52:4
Bhattacharyya B, Munda J (2003) Experimental investigation on the influence of electrochemical machining parameters on machining rate and accuracy in micromachining domain. Int J Mach Tool Manu 43:1301–1310
Malapati M, Sarkar A, Bhattacharyya B (2011) Frequency pulse period and duty factor effects on electro- chemical micromachining (EMM). Adv Mater Res 264–265:1334–1339
Xu L, Pan Y, Zhao C (2016) Distance effects in electrochemical micromachining. Nat Sci Rep 6:31778. https://doi.org/10.1038/srep31778
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Mouliprasanth, B., Hariharan, P. Scaling approach towards electrochemical micromachining: a method to evaluate similarity. Int J Adv Manuf Technol 108, 3231–3249 (2020). https://doi.org/10.1007/s00170-020-05604-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-020-05604-3