The tool geometrical shape and pulse-off time of pulse voltage effects in a Pyrex glass electrochemical discharge microdrilling process

Abstract

Electrochemical discharge machining (ECDM) is found to be a potential process for the microdrilling of glass wafers. However, some degree of heat-affected zone resulting from the thermal energy during ECDM produces several inherent problems that might be major issues, such as over cut and taper hole. To improve the quality of the ECDM microhole, a flat sidewall–flat front tool electrode is designed to reduce taper phenomena due to the sidewall discharge. In addition, a pulse voltage is applied to improve the heat-affected zone in the rectified dc voltage. The experimental results show that the combination of flat sidewall–flat front tool and pulse voltage conspicuously increases the machining accuracy while retaining the machining rate. This experimental investigation provides a new method that overcomes the disadvantages of conventional ECDM.

Multi-response optimization of WEDM parameters on machining 16MnCr5 alloy steel using Taguchi technique

“…The surface roughness slightly increases from 40 to 45 µm and then tends to decrease with increase in the pulse off time from 40 to 50 µm. This is due to the fact that when the pulse off time increases, the number of discharge decreases (Zheng et al 2007). Since the off time means the pause between the two successive sparks, therefore, the time period between the two sparks increases.…”

Building micro and nanosystems with electrochemical discharges

“…The following strategies were explored so far: optimizing the tool-electrode shape, promotion of the electrolyte flow by tool-electrode motions (e.g., tool vibrations [51][52][53][54] and tool rotation [48,52,55,56]), electrolyte motion [57] and flushing of the micro-hole in function of the measured force exerted on the toolelectrode [53,58]. • Optimizing heat transferred to the work-piece: Controlling the heat generated can be achieved passively or actively.…”

Effect of Duty Ratio at Different Pulse Frequency during Hole Drilling in Ceramics Using Electrochemical Discharge Machining

“…ECDM is a combination of the two non-conventional machining methods, namely; electro chemical machining (ECM) and electrical discharge machining (EDM) [2]. The common nonconventional methods used to fabricate the holes in nonconductive work pieces are abrasive jet machining and ultrasonic machining [3,4]. However, the application of these processes are restricted due to poor material removal rate, high tool wear, poor surface finish and geometrical inaccuracy [4].…”

“…The common nonconventional methods used to fabricate the holes in nonconductive work pieces are abrasive jet machining and ultrasonic machining [3,4]. However, the application of these processes are restricted due to poor material removal rate, high tool wear, poor surface finish and geometrical inaccuracy [4]. Therefore, ECDM is an alternative approach to machine the nonconductive work materials.…”