Abstract
Pulse electrochemical micromachining (PECMM) is an unconventional manufacturing method suitable for the production of micro-sized components on a wide range of electrically conductive materials. PECMM in this study has been used to manufacture microtools. The non-contact nature of PECMM has necessitated the modeling of the process to estimate the anodic profile (microtool profile). This paper presents a mathematical model for predicting the diameter of the microtools fabricated by PECMM process. Tungsten microtools of diameters less than 100 μm were fabricated using an in-house built microelectrochemical machining system. Experimental results confirm the theoretical prediction of reduction in tool diameter with respect to increasing machining time. Further, from the experimental verification, it was found that the deviations in the tool diameters were within 9 % of the theoretical predictions.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Schuster R, Kirchner V, Allongue P, Ertl G (2000) Electrochemical micromachining. Science 289(5476):98–101. doi:10.1126/science.289.5476.98
McGeough JA (1974) Principles of electrochemical machining. Chapman and Hall, London
Bo Hyun K, Shi Hyoung R, Deok Ki C, Chong Nam C (2005) Micro electrochemical milling. J Micromech Microeng 15(1):124
Mithu M, Fantoni G, Ciampi J (2011) The effect of high frequency and duty cycle in electrochemical microdrilling. Int J Adv Manuf Technol 55(9):921–933. doi:10.1007/s00170-010-3123-3
Kim BH, Na CW, Lee YS, Choi DK, Chu CN (2005) Micro electrochemical machining of 3D micro structure using dilute sulfuric acid. CIRP Ann Manuf Technol 54(1):191–194. doi:10.1016/s0007-8506(07)60081-x
Mathew R, James S, Sundaram MM (2010) Experimental study of micro tools fabricated by electrochemical machining. ASME Conf Proc 2010(49460):73–80
Dabholkar A, Sundaram MM (2012) Study of micro-abrasive tool-making by pulse plating using Taguchi method. Mater Manuf Process 27(11):1233–1238. doi:10.1080/10426914.2012.663143
Ghoshal B, Bhattacharyya B (2013) Influence of vibration on micro-tool fabrication by electrochemical machining. Int J Mach Tool Manuf 64:49–59. doi:10.1016/j.ijmachtools.2012.07.014
Liu Y, Zhu D, Zeng Y, Yu H (2010) Development of microelectrodes for electrochemical micromachining. Int J Adv Manuf Technol 55(1–4):195–203. doi:10.1007/s00170-010-3035-2
Fan Z-W, Hourng L-W, Wang C-Y (2010) Fabrication of tungsten microelectrodes using pulsed electrochemical machining. Precis Eng 34(3):489–496. doi:10.1016/j.precisioneng.2010.01.001
Mathew R, Sundaram MM (2012) Modeling and fabrication of micro tools by pulsed electrochemical machining. J Mater Process Technol 212(7):1567–1572. doi:10.1016/j.jmatprotec.2012.03.004
Kamaraj AB, Sundaram MM, Mathew R (2013) Ultra high aspect ratio penetrating metal microelectrodes for biomedical applications. Microsyst Technol 19(2):179–186. doi:10.1007/s00542-012-1653-3
Guo S, Guo ZN, Luo HP, Gu WC (2011) Experimental research of electrochemical mechanical polishing (ECMP) for micro tool electrode. Adv Mater Res 314–316:1846–1850. doi:10.4028/www.scientific.net/AMR.314-316.1846
Rajurkar KP, Wei B, Kozak J, McGeough JA (1995) Modelling and monitoring interelectrode gap in pulse electrochemical machining. CIRP Ann Manuf Technol 44(1):177–180. doi:10.1016/s0007-8506(07)62301-4
Kozak J, Rajurkar K, Makkar Y (2004) Selected problems of micro-electrochemical machining. J Mater Process Technol 149(1–3):426–431. doi:10.1016/j.jmatprotec.2004.02.031
Rajurkar KP, Levy G, Malshe A, Sundaram MM, McGeough J, Hu X, Resnick R, DeSilva A (2006) Micro and nano machining by electro-physical and chemical processes. CIRP Ann Manuf Technol 55(2):643–666. doi:10.1016/j.cirp.2006.10.002
Kozak J (1998) Mathematical models for computer simulation of electrochemical machining processes. J Mater Process Technol 76(Compendex):170–175
Kozak J, Rajurkar KP, Wei B (1994) Modelling and analysis of pulse electrochemical machining (PECM). J Eng Ind 116(3):316–323
Kozak J, Dabrowski L, Osman H, Rajurkar KP (1991) Computer modelling of electrochemical machining with rotating electrode. J Mater Process Technol 28(1–2):159–167. doi:10.1016/0924-0136(91)90215-z
Sarkar S, Mitra S, Bhattacharyya B (2004) Mathematical modeling for controlled electrochemical deburring (ECD). J Mater Process Technol 147(2):241–246
Ma N, Xu W, Wang X, Tao B (2010) Pulse electrochemical finishing: modeling and experiment. J Mater Process Technol 210(6–7):852–857. doi:10.1016/j.jmatprotec.2010.01.016
Volgin V, Davydov A (2012) Mass-transfer problems in the electrochemical systems. Russ J Electrochem 48(6):565–569. doi:10.1134/s1023193512060146
Minazetdinov NM (2009) A hydrodynamic interpretation of a problem in the theory of the dimensional electrochemical machining of metals. J Appl Math Mech 73(1):41–47. doi:10.1016/j.jappmathmech.2009.03.009
Minazetdinov NM (2009) A scheme for the electrochemical machining of metals by a cathode tool with a curvilinear part of the boundary. J Appl Math Mech 73(5):592–598. doi:10.1016/j.jappmathmech.2009.11.012
Zhiyong L, Zongwei N (2007) Convergence analysis of the numerical solution for cathode design of aero-engine blades in electrochemical machining. Chin J Aeronaut 20(6):570–576. doi:10.1016/s1000-9361(07)60084-3
Zhu D, Wang K, Qu NS (2007) Micro wire electrochemical cutting by using in situ fabricated wire electrode. CIRP Ann Manuf Technol 56(1):241–244. doi:10.1016/j.cirp.2007.05.057
Wu J, Wang H, Chen X, Cheng P, Ding G, Zhao X, Huang Y (2012) Study of a novel cathode tool structure for improving heat removal in electrochemical micro-machining. Electrochim Acta 75:94–100. doi:10.1016/j.electacta.2012.04.078
Deconinck D, Van Damme S, Deconinck J (2012) A temperature dependent multi-ion model for time accurate numerical simulation of the electrochemical machining process. Part I: theoretical basis. Electrochim Acta 60:321–328. doi:10.1016/j.electacta.2011.11.070
Deconinck D, Damme SV, Deconinck J (2012) A temperature dependent multi-ion model for time accurate numerical simulation of the electrochemical machining process. Part II: numerical simulation. Electrochim Acta 69:120–127. doi:10.1016/j.electacta.2012.02.079
Rajurkar KP, Kozak J, Wei B, McGeough JA (1993) Study of pulse electrochemical machining characteristics. CIRP Ann Manuf Technol 42(1):231–234. doi:10.1016/s0007-8506(07)62432-9
Loutrel SP, Cook NH (1973) A theoretical model for high rate electrochemical machining. J Eng Ind 95(4):1003–1008
Wei B (1994) Modeling and analysis of pulse electrochemical machining. University of Nebraska–Lincoln, Lincoln
Kozak J (2004) Thermal models of pulse electrochemical machining. Bull Pol Acad Sci Chem 52(4):313–320
Balsamy Kamaraj A, Dyer R, Sundaram MM (2012) Pulse electrochemical micromachining of tungsten carbide. In: ASME 2012 International Manufacturing Science and Engineering Conference (MSEC2012), University of Notre Dame, Notre Dame, IN, USA
Zhang Y (2010) Investigation into current efficiency for pulse electrochemical machining of nickel alloy. Thesis, University of Nebraska–Lincoln, Lincoln
Pourbaix M (1974) Atlas of electrochemical equilibria in aqueous solutions. NACE, Houston, p 644
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kamaraj, A.B., Sundaram, M.M. Mathematical modeling and verification of pulse electrochemical micromachining of microtools. Int J Adv Manuf Technol 68, 1055–1061 (2013). https://doi.org/10.1007/s00170-013-4896-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-4896-y