Review on Recent Advances, Research Trends, and Gas Film in Electrochemical Discharge-Based Micromachining

Abstract

Electrochemical discharge machining (ECDM) is distinguished as a novel process that involves thermal heating and chemical dissolution for the micro-machining of "difficult-to-machine" materials like ceramics, quartz. This paper comprehensively reviews the study on gas film, the effect of various input parameters on ECDM performance, such as electrical parameters, electrolyte parameters, and tool electrode parameters, are also likewise discussed. Moreover, a summarized report on thermal modeling, gas film, discrete input parameters, hybridization, and variants in the ECDM process are also provided in a lucid manner. Based on the review, it is concluded that the machining performance of the ECDM process especially in terms of MRR, roughness, tool wear, and thermal cracks are strongly influenced by the input parameters. The formation of the gas film induces variable machining features that can be controlled by altering the machining conditions. Additionally, the paper highlights the future areas that may leads to improve the overall machining performance of the ECDM process.

Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining

“…On the electrode surface, gas nucleation first occurs at several random locations and expands to the surrounding areas by absorbing the generated gases until they merge to the neighboring patches of gas pockets . The newly generated gases inside smaller bubbles are transported into a larger bubble due to the pressure difference, resulting in the continuous growth of large bubbles or a gas film. , The resident bubbles are governed by the buoyancy and surface tension, which depends on the input parameters (voltage, rotating speed, etc. ) , and, especially, the surface wettability.…”

“…25 The newly generated gases inside smaller bubbles are transported into a larger bubble due to the pressure difference, resulting in the continuous growth of large bubbles or a gas film. 26,27 The resident bubbles are governed by the buoyancy and surface tension, which depends on the input parameters (voltage, rotating speed, etc.) 28,29 and, especially, the surface wettability.…”

3D finite element modeling and multi-objective optimization for controlling the electrochemical discharge drilling parameters using the tool feed monitoring system

“…Till then, ECDD has successfully applied for drilling non-conductive materials with ease and effectiveness by amalgamating the machining properties of electric discharge (EDM) 2 and chemical machining (ECM). 3 Glass micro-holes are considered as a pioneer feature in micro-electro-mechanical systems (MEMS) applications and labs on chips devices. 4 It is known by several other names such as electrochemical arc machining (ECAM) 5 and spark assisted chemical engraving (SACE).…”