Problematic areas in micro-electrochemical milling of HSTR alloys

Mishra, K.; Gupta, Suraj; Bhattacharyya, B.

doi:10.1007/s00170-020-06109-9

Cited by 9 publications

(2 citation statements)

References 10 publications

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“…However, the rotation of such a micro-tool at low speed leads to vibration due to eccentricity. 23 Figure 10 shows the surface roughness of micro-tool rotated at a different speeds between 300 rpm and 1000 rpm. All the experiments are performed at 5V with varying rotational speed.…”

Section: Surface Finish Of Fabricated Micro-toolmentioning

confidence: 99%

Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining

Kumar

Yadav

Kumar

et al. 2021

Journal of Micromanufacturing

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Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.

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Section: Surface Finish Of Fabricated Micro-toolmentioning

confidence: 99%

Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining

Kumar

Yadav

Kumar

et al. 2021

Journal of Micromanufacturing

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“…When pulse on-time is less than pulse off-time, the sludge can be completely removed from the machine zone without the involvement of any external mechanical force. 11 The material removal in the ECM process is governed by Faraday's law of electrolysis, but in the case of EMM, the initial inter-electrode gap is very small, generally kept below 50 μm. In the electrolytic cell, when two metal electrodes are placed into an electrolyte solution, an equilibrium potential difference can be established between the metal and the solution.…”

mentioning

confidence: 99%

Anodic Polarization Study of Step Pulse Waveform for Machining Accuracy in Electrochemical Micromachining

Panda¹,

Mishra²,

Bhattacharyya³

2022

J. Electrochem. Soc.

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Electrochemical micromachining (EMM) shows promise as a versatile process for machining chemically resistant metallic materials in microsystems applications. A traditional rectangular pulse pattern has been modified into a step pulse waveform with a series of short rectangular pulses with different amplitudes. By establishing the experimental setup, anodic polarization behavior has been investigated throughout the dissolution process with 0.1M H2SO4 electrolyte solution at different applied voltages under the application of rectangular and step pulse waveforms. Utilizing the step pulse waveform, oscillation of the anode potential and transpassive state have been obtained during machining. Thus, from polarization studies, it has been observed that at 13 V, the current density is accelerated in a moderate range, i.e., 0 to 33A/cm2, which can reduce the anodic dissolution rate during the active state. Alternatively, the stray current effects and micro-sparks can be controlled because the duration of the passive state is very small and the RMS voltage can be reduced by 20.65% as compared to the rectangular pulse waveform. Further, overcut and tapering effects have been reduced by 83.99% to 51.39% and by 98.66% to 44.48% at the applied voltage of 13 to 17 V, respectively.

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