Review On Preceding And Perspective Research In Electrochemical Discharge Machining

Electrochemical discharge machining is an adaptable machining measure for miniature boring, miniature finishing, and miniature cutting of an assortment of glasses, ceramics, and composites. Electrochemical discharge machining (ECDM), otherwise called flash-assisted compound etching, is a successful miniature machining measure for non-leading materials. It has appeal in Micro Electro Mechanical System (MEMS) applications. Electrochemical discharge machining has ended up being a productive miniature machining measure and altogether utilized for the machining of non-conductive materials. Electro Chemical Discharge Machining (ECDM) is a controlled metal-evacuation measure that is utilized in metal elimination through electric flash disintegration. Because of advancements in technology, the scaled-down products have gained advantages in Lab-on-a-chip devices, including micro-electromechanical frameworks. Electrochemical discharge machining has done a good job of generating miniature openings and channels on electrically non-conductive materials, and it has emerged as a potential competitor. This paper examines the state of craftsmanship in various areas of electrochemical discharge machining, including the workpiece, electrolyte, hardware terminal behavior, gas film arrangement, machining efficiency, and late hybridizations in electrochemical discharge machining. The conclusion focuses on or summarizes potential exploration trends for improving ECDM proficiency also addresses machining issues.

Influence of Different Tool Electrode Materials on Electrochemical Discharge Machining Performances

Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.

Influence of Electrochemical Discharge Machining Parameters on Machining Quality of Microstructure

As a nontraditional processing technology, Electrochemical discharge machining (ECDM) can precisely process glass and engineering ceramics. This technology has proven to be a potential process for glass 3D microstructure. However, the key to expanding the application of ECDM is how to improve machining accuracy. This research conducted micro-hole and microgroove machining. The influence of power voltage and frequency on hole processing efficiency, hole entrance diameter and hole limit depth explored. We considered four factors affecting ECDM–the voltage and frequency of the pulse power supply, the tool electrode feed rate, and the rotation speed. We studied their influence on the roughness of the microgrooves. The results show that machining efficiency, entrance diameter and limit depth of micro-holes increased with the increase in voltage, but decreased with the increase in power frequency. The results show that the roughness of microgrooves has an obvious positive correlation with the power voltage, while it had an obvious negative correlation with the power frequency and the electrode speed. The bottom surface roughness of microgrooves can be as small as 0.605µm. Various complex 3D microstructures on the glass surface by layer-by-layer method, which proved the great potential of ECDM.