The Improvement of Machining Accuracy on Quartz and Glasses by Electrochemical Discharge Machining

Abstract

In the present study, a tungsten rod with diameter of 100μm is used as the tool to drill a quartz plate by Electrochemical Discharge Machining (ECDM). KOH solution mixed with different concentration of Ethanol is used as the electrolyte. The influences of different working parameters, such as electrolyte concentration, applied voltage, pulse frequency, and electrolyte level, on the gas film stability, gas film thickness, and machining accuracy are investigated. The experimental results show that the overcut and surface roughness is improved by the use of electrolyte with addition of 6.5wt% ethanol. The effect of gaseous bubbles is reduced during the machining, and the circulation of electrolyte is better. Compared with machining with pure KOH electrolyte, the overcut is reduced around 57% by the use of electrolyte with addition of 6.5wt% ethanol. The heat-effected zone on the machining is also largely reduced.

Effect of Electrolyte Level during Electro Chemical Discharge Machining of Glass

“…Similar findings were reported. 16 HAZ and OC were minimum at 0.1 mm electrolyte level but edge of hole was burned as observed in microscopic image in Figure 3a at this level. This is attributed to concentrated spark.…”

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

“…Hourng et al [107] mentioned that the electrolyte level would influence the machining capacity and quality while investigating the effect of different process parameters with KOH solution mixed with ethanol. It was found that with a 1 mm increase in electrolyte level, there was an increment of around 22.5% was observed in the overcut.…”