Electrochemical discharge machining of microchannels in glass using a non-Newtonian fluid electrolyte

Zou, Zhixiang; Guo, Zhongning; Zhang, Kai; Xiao, Yingjie; Yue, Tai Man; Liu, Jiangwen

doi:10.1016/j.jmatprotec.2022.117594

Cited by 13 publications

(3 citation statements)

References 24 publications

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“…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. 67 The two types of electrolytes Newtonian fluid electrolyte (KOH) and electrolyte of non-Newtonian fluid (mixture of Polyacrylamide and KOH) of different concentrations were used in the experiment performed by Zou et al 68 The experiment shows that a more stable and thin gas layer is obtained in the non-Newtonian fluid electrolyte, leading to a stable electric discharge and a lower critical voltage since there is less impact force on the gas film. The machining depth increased by about 46% in non-Newtanian fluid as compared with the KOH electrolyte.…”

Section: Electrolytementioning

confidence: 99%

Process capability of electrochemical discharge machining: A review

Prakash,

Kumar,

Ballav

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Electrochemical discharge machining (ECDM) is a hybrid machining formed by combining the principles of electrochemical machining and electrical discharge machining. The ECDM is unconventional micromachining that can fabricate holes, blind holes, micro-cavities and grooves on brittle insulating materials such as quartz, glass, silicon wafers and different composites that are difficult to machine. These non-conducting materials have sundry applications such as Micro Electric-Mechanical Systems, biomedical and electronics items. The ECDM provides maximum material removal rate and good surface quality with minor tool wear. The study describes how different process parameters affect machining. The assessment mainly focuses on various tool electrode geometries and materials that are used in ECDM. The present article investigates the ramifications of different types of electrolytes and additives mixed in electrolytes used during the ECDM process on the machined zone. This paper comprehensively reviews the effect of change in applied voltage, machining gap and an inter-electrode gap in the ECDM and it also analyses the fabrication of different materials including glass, quartz, ceramics and composites.

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Section: Electrolytementioning

confidence: 99%

Process capability of electrochemical discharge machining: A review

Prakash,

Kumar,

Ballav

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…However, the process requires a complex fabrication system. Electrochemical discharge machining (EDCM) is a hybrid machining process of electrodischarge machining (EDM) and electrochemical machining (ECM), in which the material is removed through thermal energy melting [11,12]. EDCM can be processed as both conducting and nonconducting, and a microchannel can be machined on a glass substrate.…”

Section: Introductionmentioning

confidence: 99%

Effect of a Photolithography Polymer Mask’s Dynamic Viscoelasticity on Microchannel Cross-Sectional Shapes of Glass Processed by Micropowder Blasting

Takada,

Hamamoto,

Yagyu

2024

Micromachines

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In this study, a micropowder blasting system with varying processing temperatures was proposed to control the cross-sectional shape of a channel processed on a glass substrate. Based on an analysis of the processing temperature-dependence of the dynamic viscoelastic properties of a commercial mask material for micropowder blasting, a processing temperature control system that can be installed in a micropowder blasting machine was designed. The erosion of the mask during micropowder blasting depended on the loss tangent in dynamic viscoelasticity, and showed a maximum value at a processing temperature of 100 °C. Moreover, we confirmed that the maximum decrease in the width of the processed microchannel was 30 µm (12%) by mask erosion, and this change was large compared with the maximum change in the thickness of the eroded mask. These results clarified that varying the processing temperature using a mask could control the cross-section of the processed line pattern profile on glass, and a small-width channel was realized at a processing temperature of 109 °C.

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“…The integration of non-Newtonian fluids into abrasive machining processes represents a significant advancement in addressing the challenges inherent in traditional methods [21][22][23]. Unlike Newtonian fluids, which follow linear viscosity patterns, non-Newtonian fluids exhibit diverse rheological behaviors such as viscoelasticity and thixotropy [24,25].…”

Section: Introductionmentioning

confidence: 99%

Recent Development of Abrasive Machining Processes Enhanced with Non-Newtonian Fluids

Zhu,

He,

et al. 2024

Coatings

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Abrasive machining processes have long been integral to various manufacturing industries, enabling precise material removal and surface finishing. In recent years, the integration of non-Newtonian fluids has emerged as a promising strategy to enhance the performance and efficiency of these processes. This review paper provides a comprehensive overview of the current state of research on abrasive machining processes, including abrasive lapping, abrasive polishing, and chemical mechanical polishing, and then analyzes in detail the abrasive machining processes enhanced with non-Newtonian fluids. It explores the fundamental principles underlying the rheological behavior of non-Newtonian fluids and their application in abrasive machining, with a focus on shear-thickening fluids. The paper will begin by introducing the abrasive machining processes, including abrasive lapping, abrasive polishing, and chemical mechanical polishing. Then, the current research status of non-Newtonian fluids will be comprehensively analyzed, and we will explore the enhancement of abrasive machining processes with non-Newtonian fluids. Finally, the paper will conclude with a discussion of the future directions and challenges in the field of abrasive machining enhanced with non-Newtonian fluids. Overall, this review aims to provide valuable insights into the potential benefits, limitations, and opportunities associated with the use of non-Newtonian fluids in abrasive machining, paving the way for further research and innovation in this promising area of manufacturing technology.

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Electrochemical discharge machining of microchannels in glass using a non-Newtonian fluid electrolyte

Cited by 13 publications

References 24 publications

Process capability of electrochemical discharge machining: A review

Process capability of electrochemical discharge machining: A review

Effect of a Photolithography Polymer Mask’s Dynamic Viscoelasticity on Microchannel Cross-Sectional Shapes of Glass Processed by Micropowder Blasting

Recent Development of Abrasive Machining Processes Enhanced with Non-Newtonian Fluids

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