Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.
KumarA, KumarMAlokA and DasM.Surface texturing by electrochemical micromachining: a review. IOP Conf Ser Mater Sci Eng2020; 804(1): 012011. DOI: 10.1088/1757-899X/804/1/012011
2.
OliaeiSNB, KarpatY, DavimJP, PerveenA.Micro tool design and fabrication: a review. J Manuf Process2018; 36: 496–519. DOI: 10.1016/j.jmapro.2018.10.038
3.
TakM, MishraA and MoteRG.Investigation of pulsed electrochemical micro-drilling on titanium alloy in the presence of complexing agent in electrolyte. J Micromanuf2018; 1(2): 142–153. DOI: 10.1177/2516598418784682
4.
BhattacharyyaB and MundaJ.Experimental investigation on the influence of electrochemical machining parameters on machining rate and accuracy in micromachining domain. Int J Mach Tools Manuf2003; 43(13): 1301–1310. DOI: 10.1016/S0890-6955(03)00161-5
LimY and KimSH.An electrochemical fabrication method for extremely thin cylindrical micropin. Int J Mach Tools Manuf2001; 41(15): 2287–2296.
7.
WangY, ZengY, QuN and ZhuD.Fabrication of sub-micro spherical probes by liquid membrane pulsed electrochemical etching. J Mater Process Technol2016; 231: 171–178.
8.
SahaP and DasAK.Analysis on fabrication of micro-tools by micro-electrochemical machining process. Int J Nanomanuf2013; 9(1): 66–76. DOI: 10.1504/IJNM.2013.052882
9.
DasAK, SahaP.Fabrication of cylindrical micro tools by micro electrochemical form turning operation. Proc Inst Mech Eng Part B J Eng Manuf2014; 228(1): 74–81.
10.
BhattacharyyaB.Electrochemical Micromachining for Nanofabrication, MEMS and Nanotechnology. Science Direct, 2015. DOI: 10.1016/C2014-0-00027-5
11.
FanZW, HourngLW, WangCY.Fabrication of tungsten microelectrodes using pulsed electrochemical machining. Precis Eng2010; 34(3): 489–496.
12.
KockM, KirchnerV and SchusterR.Electrochemical micromachining with ultrashort voltage pulses-a versatile method with lithographical precision. Electrochim Acta2003; 48(20–22):3213–3219. DOI: 10.1016/S0013-4686(03)00374-8
13.
PatroSK, MishraDK, ArabJ, DixitP.Numerical and experimental analysis of high-aspect-ratio micro-tool electrode fabrication using controlled electrochemical machining. J Appl Electrochem. 2020;50(2):169–184. doi:10.1007/s10800-019-01380-5.
14.
SahaS, BallAK, MukherjeeA, DasA, HalderS and HanumaiahN.Optimization of electrochemical etching process for manufacturing of micro electrodes for micro-EDM application. Proc Inst Mech Eng Part B J Eng Manuf2020. DOI: 10.1177/0954405420958961
15.
LiuZ, ZengY and ZhangW.Fabrication of metal micro-tool applying wire electrochemical machining. Adv Mech Eng2015. DOI: 10.1155/2014/382105
16.
ZhuD, WangK and QuNS.Micro wire electrochemical cutting by using in situ fabricated wire electrode. CIRP Ann—Manuf Technol2007; 56(1): 241–244. DOI: 10.1016/j.cirp.2007.05.057
17.
SinghM, JainVK, RamkumarJ.Micro-texturing on flat and cylindrical surfaces using electric discharge micromachining. J Micromanuf2020. DOI: 10.1177/2516598420980404
18.
SinghJ and BhattacharyaS.Fabrication of micro-mixer on printed circuit board using electrochemical micromachining. J Micromanuf2019; 2(2): 85–94. DOI: 10.1177/2516598419838660
19.
GhoshalB and BhattacharyyaB.Influence of vibration on micro-tool fabrication by electrochemical machining. Int J Mach Tools Manuf2013; 64: 49–59. DOI: 10.1016/j.ijmachtools.2012.07.014
20.
HsueAWJ, ChangYF.Toward synchronous hybrid micro-EDM grinding of micro-holes using helical taper tools formed by Ni-Co/diamond Co-deposition. J Mater Process Technol2016; 234: 368–382. DOI: 10.1016/j.jmatprotec.2016.04.009
21.
ZhongH, TongH, WangZ, LiY and PuY.Scanning micro-electrochemical machining process for v-shaped grooves. J Micro Nano-Manuf 2020; 8(1). DOI: 10.1115/1.4046036
22.
RajkeerthiE, HariharanP and PradeepN.Enhancing machining rate and geometrical accuracy in electrochemical micromachining of Co-Ni-Cr-W superalloy. Mater Manuf Process2021; 36(4): 488–500. DOI: 10.1080/10426914.2020.1843672
23.
MishraK, GuptaS and BhattacharyyaB.Problematic areas in micro-electrochemical milling of HSTR alloys. Int J Adv Manuf Technol2020; 111(3): 1015–1036.
24.
KunarS, MahataS and BhattacharyyaB.Influence of electrolytes on surface texture characteristics generated by electrochemical micromachining. J Micromanuf2018; 1(2): 124–133. DOI: 10.1177/2516598418765355
25.
DuttaP, BarmanA, KumarA and DasM.Design and fabrication of electrochemical micromachining (ECM) experimental setup for micro-hole drilling. In: KalamkarVR and MonkovaK (eds) Advances in mechanical engineering. Springer, 2020, pp.561–573.
26.
KumarA, SinghA, YadavHNS, KumarM and DasM.3D simulation of machining parameters of electrochemical micromachining for stainless steel (316L). Mater Today Proc February 2021. DOI: 10.1016/j.matpr.2021.01.005
