On Performance of Electrochemical Discharge Micro-Machining Process Using Different Electrolytes and Tool Shapes

The electro-chemical discharge micro-machining (µ-ECDM) process can be utilised as a potential micro-machining process, which offers several advantages such as cost-effectiveness and diversity in applications on electrically non-conducting hard brittle materials like glass. The present research article includes the analysis of material removal rate (MRR), width of cut (WOC), heat affected zone (HAZ), and surface roughness (Ra) during µ-channeling on glass with a micro-ECDM process, considering applied voltage (V), electrolyte concentration (wt%), and tool shapes as process parameters. A comparative study is conducted to select the suitable tool shape and electrolyte. Moreover, the optical and SEM images are used to examine HAZ, WOC and topography of µ-channels. MRR and WOC enhance with the rise of applied voltage for fixed electrolyte concentration and vary with tool shape. Surface roughness (Ra) is found low at applied voltage of 55V and 60V for both electrolytes when straight and curved tools, respectively, are used. The straight tool shape is more suitable for µ-channeling on glass by µ-ECDM.