In the present scenario, the demand for microfluidic channel fabrication in various industries, such as medicine, microreactors, micro heat exchangers, space, etc., has increased. The primary requirements to make the process suitable for industrial applications are repeatability and surface integrity. Therefore, various approaches have been applied to improve ECDM process characteristics, that is, sonification of tool, worktable vibration, tool rotation and magnetic field assistance. Microchannel fabrication using rotary magnetic field-assisted ECDM has not been reported in published literature. Rotary magnetic field assistance with ECDM improves the performance compared to conventional ECDM and static magnetic field-assisted ECDM. Therefore, the present work demonstrates a novel approach of rotary magnetic flux to fabricate microchannels in the glass substrate. A Rotating magnetic field generates uniform electrolyte circulation, providing a low-intense spark with thin film accumulation. It also significantly reduces width overcut by 19% and 7% compared to conventional and static magnetic field ECDM. Nature-inspired algorithms are also applied here to get the optimal voltage, concentration, magnetic flux rotation, and magnetic strength setting. These optimal settings are 38V, 10%, 5000 rpm, and 150mT, respectively.
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