Experimental investigation of tool geometry and electrolyte type effects on material removal rate, overcutand surface finish of glass micro-drilling using ECDM process

The present research deals with the experimental study ofthe effects of tool shape and applied voltage on materialremoval rate of glass micro drilling using the ECDMprocess. In this study, three different tools includingcylindrical rod, micro-drill and micro-mill with variousapplied voltages are examined and the achievedmachining speeds and the relevant patterns during theprocess are discussed. The obtained results show that themicro-drill has the highest MRR in different processconditions while the cylindrical rod results in the worstmachining speed because of its poor electrolytecirculation effects. In addition to the tool shape, increasein the applied voltage results in increase in MRR in thecase of different tool shapes.Experimental results show that in comparison withNaOH, using KOH as electrolyte results in a highermaterial removal rate. Photos taken from the surface andbottom of the holes show that with NAOH as electrolyteovercut is larger and precision is lower, also the bottomsurface of the holes has a better finish which is due to thesuperior etching of KOH.

کلیدواژه ها:

Electrochemical discharge machining(ECDM) ، glass ، micro machining ، tool electrode ، over cut