Effect of loose abrasive mixed electrolyte on the aspect ratio of blind holes drilled in soda-lime glass by ECDM process

Abstract

Electro-Chemical Discharge Machining (ECDM) process has the potential to machine various features and 3D surfaces on glass. However, machining of high aspect ratio micro holes is a challenging problem in ECDM process. In ECDM process, the machining rate mainly depends on the availability of the electrolyte at the electrode tip. Machining accuracy like taper, entry and exit diameter of the hole at high depths is rigorously affected due to lack of electrolyte at the machining zone resulting in more taperness. Low surface qualities (i.e. more over cut and tapered micro holes) are few limitations of the process. To enhance the machining capabilities a novel approach of PMECDM has been conducted. Present study is mainly focused on behavior of abrasive particles while machining soda lime glass, also studied effect of process parameters on the responses such as machining depth, outer diameter and aspect ratio. Also, the study led to analyze the effect of thermal properties of abrasives on machining performance of ECDM process. The maximum machined depth achieved was 2.31 mm in 5 min, and tremendous reduction of outer diameter from 1237.37 μm to 712.8 μm. Response surface methodology has been used to plan the experiments and ANOVA has been used to analyze the impact of each process parameters on machined depth and outer diameter of the micro holes.

Process capability of electrochemical discharge machining: A review

“…65 The metallic (Cu) and oxide (Al 2 O 3 ) nanomaterial dispersed in the electrolyte used in the ECDM increase the depth of the hole by 21.1% and 18.7%, respectively. 66 In one more study, the electrolyte was mixed with the abrasive particle to encourage ECDD of the blind hole on the soda lime glass with precision machining. The outer diameter of through a hole drilled with the conventional electrolyte, SiC mixed electrolyte and Al 2 O 3 mixed electrolyte has the value of 1237.37 µm, 712.8 µm and 821 µm, respectively.…”

Effect of Machining Limiting Factors on Drilling Progress during Spark Assisted Chemical Engraving (SACE): General Trends

“…These include modifying the tool shape, including using flat sidewall-flat front tool [7], side-insulated tool [8], drill bit [9], helical tool with high-speed rotation [10], internally structured tube electrode [11] and spherical tip tool [12]. Other attempts include using pulsed voltage [13,14], modifying the electrolyte constituents [15,16], adding tool motion such as rotation [17] and orbital motion [18], adding tool vibration [19], vibrating electrolyte [20] and doing magnetic assisted field machining [21,22]. It was also shown that deeper holes could be established through adding pressurized electrolyte flow [23] and by applying counter-resistant feeding through reducing the magnitude of contact force between the tool and substrate as drilling progresses [24].…”