PSG COLLEGE OF TECHNOLOGY

Dept. of Production Engineering

"ELECTROCHEMICAL SPARK MICROMACHINING PROCESS”

topic: Developments in electrochemical discharge machining: A review on
electrochemical discharge machining, process variants and their hybrid methods
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
Electro chemical discharge Machining Variant
Electrochemical Discharge Drilling (ECDD) and its effectiveness in achieving
high machining rates and accuracy:
1. Formation of Gas Film: The rapid formation of a gas film increases the discharging frequency and Material Removal Rate
(MRR), ultimately leading to better machining rates.
2. Effect of Tool Electrode Geometry: Compared to a conventional cylindrical electrode, a tool electrode with a spherical tip
significantly reduces machining time and hole diameter during the fabrication of deep holes.
3. Tool Wear: Tool wear is a crucial factor influencing machining accuracy in ECDD. Steel and tungsten carbide tools generally
perform better than brass tools in terms of tool wear.
4. Variability in Hole Shapes: ECDD allows for the drilling of high aspect ratio holes as well as holes with conical and spherical
cross-sections. The choice of tool electrode polarity (cathodic or anodic) influences the shape of the drilled holes.
5. Role of Polarity in Chemical Etching: The polarity of the tool electrode affects the electrochemical action, i.e., chemical
etching, during the drilling process. Cathodic polarity leads to a decrease in hydroxyl radical concentration along the hole depth,
resulting in conical cross-section holes, while anodic polarity produces a uniform concentration of hydroxyl radicals, enabling the
drilling of holes with spherical cross-sections.
6. Surface Finish: Chemical etching action over the spark-discharged machined surface results in a smooth surface finish,
contributing to the overall quality of the drilled holes
Overall, these findings highlight the complex interplay between process parameters, tool geometry, polarity, and chemical
reactions in ECDD, ultimately affecting machining rates, accuracy, and surface finish.
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…
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.
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.
important process parameters that directly controls the discharge energy over the machining zone. Thus, the accuracy of machined micro holes is characterized as a function of
machining voltage and drilling depth The resultant mean diameter obtained from the various combinations of machining voltage and drilling depth is identified into three zones,
namely,
the integration of different energy sources in Electrochemical Discharge
Machining (ECDM) processes to enhance their performance. Here's a breakdown
of

1. Combination of Energies: Researchers have combined electrochemical and electro discharge energies to perform various
operations such as drilling, milling, and turning. This combination aims to improve the efficiency and effectiveness of ECDM-
based operations.
2. Triplex Hybrid Methods: To further enhance ECDM performance, researchers have developed triplex hybrid methods by
introducing a third energy source or interaction. These methods are classified into primary and secondary hybrid processes
based on the nature of the third energy source or interaction.
3. Primary Hybridization: Primary hybridization involves mixing the third energy source with ECDM through methods such as
tool rotations or adding powders to the electrolyte.
4. Secondary Hybrid Processes: Secondary hybrid processes utilize mechanical or magnetic forces to assist in material
removal. These forces augment the primary electrochemical discharge energy.
5. Role of Primary Energy: In these hybrid processes, the primary energy source for material removal remains electrochemical
discharge.
Overall, the integration of multiple energy sources in ECDM processes through triplex hybrid methods offers the potential for
improved performance and versatility in various machining operations.
ECDM based triplex hybrid method
R –ECDM PROCESS
a primary triplex hybrid method called Rotary Electrochemical Discharge Machining (R-ECDM), which involves the rotary motion of
the tool electrode during the ECDM process. Here's a breakdown of the key points:
1. R-ECDM Process: In R-ECDM, the tool electrode undergoes rotary motion while performing the electrochemical discharge
machining. This rotary motion is a primary hybridization method, combining the electrochemical and rotary motion energies.
2. Advantages: The advantage of R-ECDM lies in its ability to drill straight holes with small entrance diameters. The rotary motion of
the tool electrode facilitates this capability, allowing for precise machining.
3. Uniform Distribution of Spark Energy: The application of tool rotation ensures that the spark energy distributes uniformly during
the machining process. This uniform distribution contributes to consistent and controlled material removal, enhancing the overall
efficiency and accuracy of the process.
Overall, R-ECDM represents an innovative approach to electrochemical discharge machining, offering improved capabilities for
drilling precise holes with small entrance diameters through the integration of rotary motion.
Powder Mixed Electrochemical Discharge Machining
The passage discusses another type of triplex hybrid method in Electrochemical Discharge Machining (ECDM) known as Powder Mixed
Electrochemical Discharge Machining (PM-ECDM). Here's a summary of the key points:
1. PM-ECDM Process: PM-ECDM involves the mixing of abrasive particles, such as graphite, in the electrolytic media used during the
machining process. This combination creates a triplex hybrid method by incorporating electrochemical, discharge, and abrasive particle
energies.
2. Surface Integrity and Repeatability: The presence of abrasive particles in the electrolytic media improves the surface integrity and
repeatability of the machining process. This enhancement leads to smoother surface finishes and better process consistency.
3. Reduction of Spark Energy Impact: The presence of conductive abrasive particles within the gas film formed during the machining
process reduces the direct impact of spark energy on the work surface. This reduction results in smoother surface finishes.
4. Behavior of Conductive Particles: Han et al. describe two ways in which conductive particles behave during the machining process:
- Tool electrode attached conductive particles intensify the electric field at local areas, resulting in stable discharges.
- Dynamic movements of abrasive particles caused by electrostatic forces lead to constant charge transfer between the tool electrode and
work surface.
5. Improved Surface Roughness: When machining materials like borosilicate glass, the addition of graphite abrasive particles to the
sodium hydroxide electrolytic solution results in improved surface roughness.
Overall, PM-ECDM offers advantages in terms of surface finish improvement, process stability, and repeatability by incorporating
abrasive particles into the electrolytic media during the ECDM process.
Magnetic-Field-Assisted Electrochemical Discharge Machining (MAECDM)

1. Introduction of Magnetic Unit: Cheng et al. introduced a magnetic unit inside the tool chuck to create MAECDM.
This method involves the use of a special magnetic tool chuck to hold the tool electrode.
2. Setup and Magnetic Field Application: The MAECDM setup includes a provision for applying magnetic fields in
both upward and downward directions. This magnetic field induces Magneto Hydrodynamic (MHD) convection in the
electrolyte.
3. Enhanced Electrolyte Circulation: MHD convection enhances the circulation of electrolyte within narrow gaps. This
improved circulation helps in breaking hydrogen gas bubbles more easily from the tool surface.
4. Stable Gas Film Maintenance: The effective circulation of electrolyte helps maintain a stable gas film over the tool
electrode, requiring higher voltage for stable machining. This higher voltage contributes to higher machining
efficiency.
5. Prevention of Gas Film Debilitation: Effective electrolyte circulation prevents the debilitation of gas film quality,
particularly during the fabrication of deep holes. A better gas film quality leads to stable discharges, thereby improving
geometrical accuracy.
6. Machining Performance Improvement: With the application of an upward magnetic field, the MAECDM process
demonstrated a 57.4% improvement in machining time and a 23.8% reduction in overcut.
Overall, MAECDM offers significant enhancements in machining efficiency and accuracy through the application of
magnetic fields to improve electrolyte circulation and gas film stability during the ECDM process.
conclusion

After inclusive analysis of presented work on developments in variants of electrochemical discharge machining (ECDM) and its triplex hybrid
methods, the major conclusions can be drawn as below.
1. Electrochemical discharge machining (ECDM) is prominent non-conventional hybrid machining process for machining of both conductive
and non-conductive materials.
2. The influential advancement of electrochemical discharge machining (ECDM) variants is fabrication of micro scaled intricate profiles on
difficult to machine materials with good surface quality and higher machining rates.
3. Electrochemical discharge dressing is emerging method that is quite suitable for dressing of worn micro-grinding tools.
4. Wire- Electrochemical discharge machining (W-ECDM) is very effective option to slice the materials, irrespective of their conductivity. 5.
Electrochemical discharge turning (ECDT) is flexible attainment of electrochemical discharge machining (ECDM) method to machine
cylindrical parts. 6. Rotary electrochemical discharge machining (R-ECDM), Vibration assisted electrochemical discharge machining (VAECDM)
and magnetic field- assisted electrochemical discharge machining (MAECDM) improve the drilling performance in terms of material removal
rate, hole depth and accuracy, while electrochemical discharge trepanning method is well suited for drilling deep holes of large diameter.
7. Electrochemical discharge grinding (ECDG) is very effective approach to finish the micro holes and cylindrical surfaces on conductive and
non-conductive materials

•
Journal 2

• Improving surface integrity of micro-holes in ECDM using ultrahigh-speed

rotary of tool cathode and non-water-based electrolyte
Jiwen SHEN, Weijing KONG, Zhengyang XU, Yongbin ZENG
Objective:
• ultrahigh-speed Rotary Electrochemical Discharge Machining (R-ECDM) using a non-water-based electrolyte to improve
the surface integrity of metal micro-hole structures.
• 1. The aim is to enhance the surface integrity of metal micro-hole structures produced by electrochemical discharge
machining (ECDM), which typically suffer from unsatisfactory surface quality due to insufficient reaction area and strength
of electrolysis action.
Methodology
• R-ECDM introduces a new process using a non-water-based electrolyte and ultrahigh rotational speeds to change the
breakdown medium of spark discharge. This alteration increases the reaction area and strengthens the electrolysis action,
leading to improved machining performance.
Mathematical Model
A mathematical model is developed to establish the relationship between rotational speed and the forces acting on bubbles formed
during the machining process. By understanding these forces, the rotational speed can be controlled to optimize bubble behavior on the
cathode surface.
Experimental Validation
Experimental Validation: High-speed photographs validate the mathematical model, showing that increasing rotational speed reduces
both the number and departure radius of bubbles on the cathode surface.
Surface Roughness Improvement:
5. Surface Roughness Improvement: Experimental results demonstrate a significant reduction in micro-hole sidewall roughness (Ra)
from 2.54 µm to 0.20 µm as rotational speed increases from 500 r/min to 40,000 r/min. This reduction indicates improved surface
quality.
6. **Cathode Wear**: The length loss and wear ratio of the cathode are minimal (9.75 µm and 6.5%, respectively), indicating that the
machining process is efficient and sustainable.
Outcome:
Outcome: The proposed R-ECDM approach successfully fabricates micro-hole arrays with recast-free surfaces and achieves a surface
roughness of 0.20 µm. This outcome demonstrates that the method contributes significantly to enhancing the surface integrity of metal
micro-holes.
• This innovative approach combines advanced machining techniques with mathematical modeling to optimize process parameters,
leading to superior surface quality and reduced cathode wear during micro-hole fabrication. The findings suggest promising
applications in precision manufacturing, particularly in industries like aerospace and engineering where high-quality micro-
machining is crucial.
conclusion

•This summary outlines a study on an ultrahigh-speed Rotary Electrochemical Discharge Machining (R-ECDM) process using a
non-water-based electrolyte to improve the surface integrity of metal micro-holes. Here are the main conclusions drawn from the
research:
1. Process Improvement Objective: The aim of the study is to enhance the surface integrity of metal micro-holes by altering the
breakdown medium of spark discharge and increasing the reaction area and strength of electrolysis action in ECDM.
2. Mathematical Model Development: A mathematical model was developed to understand the behavior of bubbles on the
cathode surface, considering forces like buoyancy, surface tension, axial thrust, and radial centrifugal force generated by
cathode rotation. This model helps establish the relationship between rotational speed and bubble behavior.
3. Bubble Behavior and Rotational Speed: The study found that the behavior and departure radius of bubbles on the cathode
surface are influenced by rotational speed. Controlling rotational speed affects bubble detachment mechanisms—bubbles
detach vertically at lower speeds (below 10,000 r/min) and horizontally at higher speeds (above 10,000 r/min).
4. Experimental Validation: High-speed camera photographs supported the mathematical model by demonstrating a decrease in
both the number and departure radius of bubbles with increasing rotational speed.
5. Surface Roughness Improvement: Experimental results confirmed that increasing rotational speed from 500 r/min to 40,000
r/min significantly reduces the surface roughness of micro-hole sidewalls from 2.54 µm to 0.20 µm. This reduction indicates
improved reaction area and strength of electrolysis action in ECDM at higher cathode speeds.
6. Material Integrity and Cathode Wear: The novel R-ECDM process preserves the chemical composition and metallographic
structure of the machined surface. Additionally, the length loss and wear ratio of the cathode are minimal (9.75 µm and 6.5%,
respectively), highlighting the efficiency and durability of the process.
7. Fabrication of Micro-hole Arrays: The optimized R-ECDM process successfully fabricates micro-hole arrays with high surface
integrity, achieving a surface roughness (Ra) of 0.20 µm and deep micro-holes without recast layers.
•In summary, the study demonstrates the effectiveness of ultrahigh-speed R-ECDM using a non-water-based electrolyte to improve
surface quality and integrity in metal micro-hole machining. The combination of mathematical modeling, experimental validation, and
optimized process parameters leads to significant advancements in micro-machining technology with applications in precision
manufacturing.
•
Journal 3

• Powder mixed electrochemical discharge process for micro machining of C103

niobium alloy
abstract
This study investigates the effectiveness of powder-mixed micro-electrochemical discharge machining (PMECDM) for fabricating
micro-holes in C103 niobium-based alloy, particularly suitable for high-temperature applications. The PMECDM process combines
three simultaneous actions—spark erosion, chemical etching, and abrasive grinding—to remove material, whereas classical micro-
electrochemical discharge machining (MECDM) involves only spark erosion and chemical etching.
Key findings and conclusions from the study include:
1. Material Removal and Surface Finish: PMECDM resulted in rapid material removal and improved surface finish compared to
MECDM. The addition of powder to the electrolyte enhances the material removal rate (MRR) while providing a smoother surface
finish.
2. Process Comparison: In terms of performance metrics, PMECDM exhibited a higher MRR of 2.8 mg/min and lower surface
roughness (Ra) of 0.61 µm compared to MECDM, which had an MRR of 2.01 mg/min and corresponding Ra of 1.11 µm. This
indicates the superiority of PMECDM for achieving efficient material removal and better surface quality.
3. Optimization and Surface Topography: The study employed a multi-objective optimization approach to identify optimal process
parameters for PMECDM. The optimized parameters led to significant improvements in MRR and surface finish, which were validated
through detailed analysis of the hole wall surface topography.
4. Detailed Analysis: The paper presents a comprehensive analysis of experimental results, focusing on the effectiveness of PMECDM
in terms of MRR and surface roughness. The study highlights the practical advantages of using PMECDM over traditional MECDM
for machining C103 niobium-based alloy.

In summary, the research demonstrates the feasibility and benefits of utilizing powder-mixed micro
introduction

The excerpt provides an in-depth overview of the challenges associated with traditional machining of niobium-
based C103 alloy and the advantages of unconventional machining processes like powder-mixed micro-
electrochemical discharge machining (PMECDM) for achieving precision micro-machining of exotic materials.
Here are
 . Advantages of Niobium-Based C103 Alloy

Advantages of Niobium-Based C103 Alloy**: C103 alloy, composed mainly of niobium (89%), hafnium (10%), and titanium (1%), is
valued for its strength retention at high temperatures and cross-resistance, making it ideal for aerospace applications in rocket nozzles,
propulsion systems, and jet engine components.
Challenges in Machining C103 Alloy

Challenges in Machining C103 Alloy: Traditional machining methods struggle with C103 alloy due to difficulties such as the
formation of a built-up edge and increased complexity when machining micro-features.
Unconventional Machining Approaches
• Unconventional Machining Approaches: Processes like micro-electrical discharge machining (μEDM), micro-electrochemical
machining (μECM), and their hybridization (micro-ECDM) are recommended for shaping C103 and similar materials due to their
ability to overcome traditional machining challenges.
Limitations of μEDM and μECM
Limitations of μEDM and μECM**: Each of these processes has limitations, including low material removal rate, tool wear, surface
roughness, recast layer deposition, and residual stresses, necessitating post-processing operations.
Role of MECDM

• Role of MECDM: Micro-Electrochemical Discharge Machining (MECDM) combines aspects of both μEDM and μECM to address
their limitations. MECDM offers better surface finish compared to μEDM and superior geometric accuracy compared to μECM.
Contd…
6. **Improvements with PMECDM**: Powder-Mixed MECDM (PMECDM) introduces abrasive particles (e.g., micro-sized Al2O3
powder) into the electrolyte to enhance material removal and surface quality. This approach helps in debris removal during the
machining process, eliminating the need for extensive post-processing.
7. **Enhancements in Performance**: Studies have shown that modifying MECDM with abrasive powders like micro-sized graphite or
SiC can further improve surface integrity, reduce cracks, and increase material removal rate.
8. **Application to Exotic Materials**: While PMECDM has been effective for non-conductive materials like glass and ceramics, its
application to exotic conductive materials like niobium-based C103 alloy remains unexplored, highlighting a research gap.
9. **Investigation and Research Aim**: The article aims to investigate the performance of PMECDM for machining niobium-based
C103 alloy and compare it with classical MECDM. The focus is on micro-hole drilling and achieving acceptable dimensional accuracy
and surface finish without the need for extensive post-processing.
10. **Principle of PMECDM**: The process involves applying voltage across tool and workpiece electrodes submerged in a powder-
mixed electrolyte. Electrochemical reactions lead to bubble formation, passivation film creation, and eventual material removal through
discharge and chemical etching actions.
In summary, the excerpt emphasizes the importance of unconventional machining methods like PMECDM for achieving precise and
efficient machining of challenging materials like niobium-based C103 alloy, with a focus on enhancing surface quality and dimensional
accuracy while reducing the need for labor-intensive post-processing operations.
conclusion
1. Significance of Applied Voltage: The applied voltage (V) was identified as the most influential parameter in both MECDM and
PMECDM processes. This parameter played a crucial role in determining material removal rate (MRR) and surface finish (Ra).

2. Effect of Powder in PMECDM: The presence of powder in the electrolyte solution in PMECDM resulted in the occurrence of
multiple sparks during machining. This contributed to improving the surface quality of the machined surface compared to MECDM.

3. Optimized Parameter Settings: Through multi-objective optimization, the optimal combination of parameters (applied voltage,
electrolyte concentration, and duty factor) was determined to achieve the highest MRR with minimum surface roughness (Ra).
Specifically, an applied voltage of 42 V, electrolyte concentration of 16 wt %, and duty factor of 35% were found to be optimal.

4. Validation of Optimization Results: Confirmation experiments demonstrated a high level of accuracy (within 5% error) in predicting
the machining performance based on the optimized parameters identified through multi-objective optimization.

5. Performance Comparison PMECDM consistently outperformed MECDM in terms of MRR and surface roughness across all
parameter settings. The highest achieved MRR of 2.8 mg/min and corresponding surface roughness (Ra) of 0.45 µm were obtained
using the PMECDM technique under optimized conditions.

These findings underscore the effectiveness of PMECDM over MECDM for micro-machining operations on C103 niobium-based
alloy, particularly in achieving higher material removal rates and improved surface finishes. The study highlights the importance of