Abstract
Electrochemical micromachining (ECMM) is used on conductive materials to make complex features on the workpiece. The application of ECMM process has been limited due to factors such as overcut and taper formation during the machining of microholes. Passivation layer formation is an important issue in ECMM. During electrochemical micromachining process, metal hydroxides are formed at the workpiece–tool interface and get accumulated between the tool and the workpiece which forms a passivation layer. This passivation layer widens the flow of current and affects the accuracy of the machined hole. In this research work, an attempt has been made to improve the circularity of the machined hole by effectively removing the passivation layer formed at the workpiece tool interface using electrolyte flushing technique (EFT). Using EFT, copper and Inconel 718 alloy were machined with brass and copper tool electrodes, respectively. Material removal rate (MRR), circularity and taper angle were considered as primary output response parameters. Various flushing flow rates of electrolyte were taken as input parameters to study the effect of oxide layers formed in and around the tool–workpiece interface. Single-factor experiment optimization techniques were used for the fabrication of microholes. The result clearly shows that the usage of EFT on micromachining removes the passivation layer under different flow rates.
This is a preview of subscription content, log in via an institution.
Buying options
Tax calculation will be finalised at checkout
Purchases are for personal use only
Learn about institutional subscriptionsReferences
Bhattacharyya, B., Munda, J., Malapati, M.: Advancement in electrochemical micro-machining. Int. J. Mach. Tools Manuf. 44, 1577–1589 (2004)
Loutrel, S.P.: Electrochemial Machining: Prediction of Operating Parameters Including Extreme Operating Conditions. Massachusetts Institute of Technology, Cambridge, MA (1971)
Bannard, J.: Electrochemical machining. J. Appl. Electrochem. 7, 1–29 (1977)
Rajurkar, K.P., Zhu, D., Wei, B.: Minimization of machining allowance in electrochemical machining. CIRP Ann. Manuf. Technol. 47, 165–168 (1998)
Zhang, Z., Wang, Y., Chen, F., et al.: A micro-machining system based on electrochemical dissolution of material. Russ. J. Electrochem. 47, 819–824 (2011)
Munda, J., Malapati, M., Bhattacharya, B.: Control of micro-spark and stray-current effect during EMM process. J. Mater. Process. Technol. 194, 151–158 (2007)
Rajurkar, K.P., Zhu, D., McGeough, J.A., Kozak, J., Silva, A.D.: New developments in electro-chemical machining. CIRP Ann. Manuf. Technol. 48, 567–579 (1999)
Ghosal, B., Bhattarcharya, B.: Influence of vibration on micro-tool fabrication by electrochemical machining. Int. J. Mach. Tools Manuf. 64, 49–59 (2013)
Zhang, Y.J., Tang, Y.J., Liu, X.K., et al.: Development of ultra-short pulse power supply applicable to micro-ECM. Mater. Sci. Forum 626–627, 369–374 (2009)
Zhang, Y., Xu, Z., Zhu, D., Xing, J.: Tube electrode high-speed electrochemical discharge drilling using low-conductivity salt solution. Int. J. Mach. Tools Manuf. 92, 10–18 (2015)
Sadagopan, P., Mouliprasanth, B.: Investigation on the influence of different types of dielectrics in EDM. Int. J. Adv. Manuf. (2015)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2019 Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Pooranachandran, K., Deepak, J., Hariharan, P., Mouliprasanth, B. (2019). Effect of Flushing on Electrochemical Micromachining of Copper and Inconel 718 Alloy. In: Vijay Sekar, K., Gupta, M., Arockiarajan, A. (eds) Advances in Manufacturing Processes. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-13-1724-8_6
Download citation
DOI: https://doi.org/10.1007/978-981-13-1724-8_6
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-13-1723-1
Online ISBN: 978-981-13-1724-8
eBook Packages: EngineeringEngineering (R0)