Abstract
Electrochemical machining is known to possess certain advantages for micromachining applications, among them very low tool deflection, and zero tool wear. However, dimensional precision is a potential drawback for this technology. Here we describe the development of a three-axis pulsed ECM machine designed specifically for machining features with dimensions less than one millimeter. Preliminary tests show that the machine is able to machine grooves in pure nickel substrates, using a 3M NaNO_3 electrolyte. The effects of electrolyte concentration, tool traversing speed, machining gap, and process parameters on metal removal and edge quality are presented.
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