PSG COLLEGE OF TECHNOLOGY

Dept. of Production Engineering

"ELECTROCHEMICAL SPARK MICROMACHINING

PROCESS"

NAME : JASHIM AHAMED A

REG NO : 23MP33
BRANCH : MANUFACTURING ENGINEERING
DATE :
 introduction

 Electrochemical discharge machining (ECDM) is a hybrid non-conventional machining process, used to

machine electrically conductive and non-conductive materials
 It is a preferred process to fabricate micro scale features
 micro holes, micro channels, microgrooves and 3-dimensional intricate shapes on variety of materials
 These augmentations result in developments of ECDM process variants.
 So research community has developed ECDM based triplex hybrid methods
What other researcher says
• represents the schematic view of the discharge mechanism that
includes the following steps
• (i) electrolysis,
• (ii) generation and accumulation of hydrogen gas bubbles,
• (iii) bubble coalesce and gas film formation,
• (iv) sparking.
Basak and Ghosh observe
This passage describes observations and findings related to a process likely involving Electrical Discharge Machining (EDM). Let's
break down the key points:
1. Narrow Conducting Bridges: Basak and Ghosh observed narrow conducting bridges within a gas film over the tool electrode. High
current densities across these bridges caused instant boiling, leading to arc discharge.
2. Gas Bubbles as Valves: Jain et al. conceptualized gas bubbles as valves. Under high electric fields, breakdown of each valve
produces arc discharge.
3. Shape of Arc Discharge: Behroozfar et al. reported that the shape of the arc discharge can be observed by capturing simultaneous
images of current signals and signatures engraved on the workpiece surface. The circular form of the signatures reflects the cylindrical
form of the arc discharge.
4. Temperature Rise and Chemical Etching: The impingement of continuous discharges over the workpiece surface increases the
temperature of the electrolyte. This elevated temperature promotes chemical etching over the machined surfaces, ultimately
contributing to achieving surface finish.
5. Complex Mechanisms: The simultaneous involvement of discharge melting and chemical etching makes the process mechanisms
very complex. Quantification of the contribution of each material removal mechanism is not reported in the literature.
In summary, the passage discusses the mechanisms underlying EDM processes, including the formation and breakdown of conducting
bridges, the role of gas bubbles, the shape of arc discharge, temperature effects, and the combined actions of discharge melting and
chemical etching for material removal.
 Contd…

This passage discusses the application of the Electrochemical Discharge Drilling (ECDD) method in microfabrication and highlights
its versatility in drilling various materials, including conductive ones like cobalt, steels, chrome, titanium, and nimonic alloys, as well
as non-conductive materials like ceramics, glass, and composites.
Key points include:
1. Material Versatility: ECDD has been used to drill a wide range of materials, including conductive materials like metals and alloys,
as well as non-conductive materials like ceramics, glass, and composites.
2. Surface Finish: Machined surfaces using ECDD typically exhibit a smooth surface finish similar to that achieved through
electrochemical machining.
3. Process Operation: ECDD involves controlled and progressive movements of the tool electrode along the z-axis, with the
interaction of these movements and discharge energy making the process complex.
4. Process Parameters: Various parameters related to the electrolyte, tool electrode, and power supply effectively control the discharge
energy in ECDD. These parameters include machining voltage and drilling depth, which directly influence the accuracy of machined
micro holes.
5. Characterization of Machined Holes: The accuracy of machined micro holes is characterized as a function of machining voltage
and drilling depth. The resultant mean diameter obtained from different combinations of these parameters is categorized into three
zones.
Overall, the passage underscores the importance of process parameters in controlling the discharge energy and achieving accurate
machining results in ECDD, particularly in micro hole drilling applications.