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INVESTIGATION OF ELECTRO CHEMICAL MICRO

MACHINING USING RETRACTED TIPPED TOOL

PAPER PRESENTATION

ABHINAYA.K.S
MAGALAKSHMI ESWARI.R.S

DEPARTMENT OF MANUFACTURING ENGINEERING

COLLEGE OF ENGINEERING ,GUINDY.

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CONTENTS

 Introduction
 Literature Survey
 Methodology
 Need and Scope of the work
 Experimentation
 Results and Discussion
 Conclusion
 Future work
 References

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INTRODUCTION

Electrochemical machining (ECM) is described as a controlled anodic


electrochemical dissolution process applied to shape desired structure .

During the machining process, specific voltage is supplied between


workpiece (anode) and tool (cathode) separated by a very narrow gap, and
appropriate electrolyte is pumped through the machining zone, resulting in
the dissolution of anode.

ECM is to overcome the thermal-mechanical effects of EBM, ELM and


EDM.

ECM has no tool wear, smooth surfaces, regardless of workpiece material


hardness, and relatively high machining rate .

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INTRODUCTION contd.,

ECM-anodic dissolution
process
workpiece and tool are
respectively anode and
cathode,
Separated by electrolyte.
Gap between anode and
cathode: IEG (inter
electrode gap)

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INTRODUCTION contd.,

ECM is often characterized as "reverse


electroplating," in that it removes material
instead of adding it.

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INTRODUCTION contd.,

 Electrochemical micromachining (ECMM) is a significant variant of


ECM to manufacture micro scale features.

 ECMM process produces more accurate and higher finish


components.

 When the ECM is applied to micromachining range (1-999 µm) for


producing ultra precision shape.

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INTRODUCTION contd.,

7
INTRODUCTION contd.,

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LITERATURE SURVEY

AUTHOR & TITLE WORK DONE RESULTS


Sandip anasane.S, Seven different types of Electrolytes with aqueous base
Bhattacharya.B, electrolytes for machining of sodium and sodium
titanium material was perchlorate can be effectively
“Experimental Investigation attempted. employed for controlled
on Suitability of electrolytes anodic dissolution of titanium
for electrochemical machining Tungsten tool of 200 µm is a material.
of titanium”. selected as tool.
Ethylene Glycol with sodium
International Journal of Different types of electrolytes bromide aqueous solution is
Advanced Manufacturing and and its effects on current the eco-friendly and cost
Technology. (2016) density, anodic dissolution, effective solution of
radial overcut, degree of taper Electrochemical
in microholes were studied. micromachining of Titanium.

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Spieser A,Ivanov A., A brief review on the The key role of the tool
electrochemical electrode characteristics have
“Recent developments and micromachining elements like also been outlined .
research challenges in power supply, tooling systems,
electrochemical electrode fabrication, Vibrating and rotating tools
micromachining”. electrolytes, IEG monitoring have been discussed to enhance
and measurement of work piece the efficiency.
International Journal of after EMM process are
Advanced Manufacturing and discussed. New method to control EMM
Technology. ( v69) , by other logic control
Pg.563-581 (2013) techniques can be implemented
for controlling IEG and
accuracy.

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Rajurkar,K,P, Sundaran Extensive review on The recent advancements in
M,M, Malshe A,P., electrochemical machining and ECM and EDM which can be
their advancements was suited for start of art
“Review of Electrochemical carried out. applications was identified.
and Electrodischarge
Machining”. ECM process parameters like ECM and EDM technologies
power supply unit, Electrolyte and their capabilities to
Proceedia CIRP Annals. ( v6) , system, IEG, types of electrode produce micro features for
Pg.513-26,(2013) and electrode materials and wide applications was studied.
their effects on various work
piece and different profile
shapes was thoroughly studied.

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Swain A,K, Sundaram,M,M, Tungsten tool of 300µm was The coated tool had higher
Rajurkar, K,P, fabricated and it is coated with material removal rate and
nickel by electro deposition produced better shape accuracy
“Use of coated tools in technique in mixture of acids in ECM experiments.
advanced manufacturing:A electrolytic bath solution.
exploratory study in Nickel coated tungsten
electrochemical machining microtool because of higher
context”. electrochemical stability and
greater corrosion resistance can
Journal of Manufacturing be used as effective tool in
Processes( v14) , microECM environment.
Pg.150-159(2012)

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Yong Liu, Zhu D., et al., Microelectrodes with various Microholes array with less than
end shapes are fabricated by 10µm and three microholes with
“Development of different processing techniques no taper and a 3D
microelectrodes for such as electrochemical etching, microstructure are machined on
electrochemical single electric discharge and the metallic materials by the
micromachining”. electrochemical types of fabricated electrodes.
micromachining are
International Journal of investigated.
Advanced Manufacturing
Technology( v55) ,
Pg.195-203,(2011)

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Bhattacharyya,B, The influence of various This paper summarizes the
Malapatti,M, Munda , J predominant factors of EMM research work carried by the
such as material removal rate, various researchers and the
“Advancements in machining accuracy, power development of EMM for
electrochemical micro- supply, design of micro tool, effective utilization of micro
machining”. role of IEG, electrolyte etc are fabrication.
investigated.
International Journal of
Machine Tools &Manufacture
( v44) ,page no.1577- The wide applications of EMM
1589,(2004) was also presented.

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Rajurkar,K.P, Mc The increasing demand of ECM The use of ECM in micro
Geough,J.A., et al., process for machining difficultfabrication and surface
to cut materials and complex finishing and hybrid ECM
“New Developments in Electro- profiles are reported. process and applications of
chemical Machining”. ECM processes are extensively
Developments in tool design, identified.
Annals of the CIRP( v48) , pulse current, micro-shaping ,
(1999) finishing, hybrid ECM process Accurate hole in the copper
are covered. plates can be machined by the
parametric combination of
machining voltage of 10V, 15g/l
concentration.

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LITERATURE SURVEY Contd..

AUTHOR & TITLE WORK DONE RESULTS


Liu W, Sansan A, Li, Wang Retracted tip tool was fabricated The fabricated retracted tip tool
et al., by etching and CVD produces high quality
process.The effect of retracted miocroholes on SS 304 and
“Modelling and fabrication of tipped tool is analysed on output aluminium sheets.
microhole by electrochemical responses like material removal
micromachining using retracted rate.
tip tool”.
Mathematical modelling is
Precision Engineering , (2017) developed.

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OBJECTIVES

 To investigate the different types of tool in electrochemical


micromachining process.

 To fabricate coated and retracted tip tool.

 To study the influence of process parameters like voltage, duty


cycle, tool feed rate, electrolyte concentration for machining
the copper sheets of 0.2 mm thickness.

 To analyse the tool suited for machining microhole profile


with better material removal rate and reduced overcut.
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METHODOLOGY

STUDY OF ECMM PROCESS

PROBLEM IDENTIFICATION

SELECTION OF WORKPIECE,
ELECTROLYTE, FABRICATION OF
TOOL SHAPES

EFFECT OF PROCESS
PARAMETERS ON ECMM

CONCLUSION

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NEED AND SCOPE OF WORK

 The need is machining of accurate microhole is a key feature for many


kinds of micro parts widely used in diverse industries.

 Machining of microhole using traditional processes faces great challenges


due to the thermal-mechanical effects.

 ECMM is a potential technique to meet the requirement of high-quality


microhole fabrication with good accuracy and also eliminates secondary
processes.

 The objective of the present work is to study the effect of the three different
tool profile on the machined hole which provides a better solution to
manufacture components with micro hole profiles.

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Tapered hole generation using ECMM

A tapered shape can be achieved by gradually increasing the pulse voltage as tool
electrode is fed from inlet to outlet at a constant velocity. Then a filleted corner at
outlet can be machined by holding tool electrode for a while. To raise machining
localization, a side insulated electrode is adopted in the ECM process. The thickness
of insulating layer should be thin enough and uniform along electrode, so that the side
insulated electrode can be fed through the pilot hole.

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EXPERIMENTATION

Tool: Copper tool of 300 µm diameter.


(Bare tool, Coated tool and Retracted Tip tool)
Work piece: Copper sheet of 200 µm thickness.
Electrolyte : Sodium Nitrate solution with distilled water.

SCHEMATIC OF ECMM SET UP


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EXPERIMENTATION contd.,

FABRICATION OF COATED TOOL:


 The micro tool made up of copper wire is taken into respective length and it
is coated by physical vapour deposition method.

 Target – Chromium pellet


Substrate – 0.3 mm copper rod
MODEL - BC-600

 BOX TYPE VACCUM COATING UNIT

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EXPERIMENTATION contd.,

FABRICATION OF RETRACTED TOOL

Two steps:
 CVD coating
 Electrochemical etching

CVD coating unit

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EXPERIMENTATION contd.,

FABRICATION OF RETRACTED TOOL :

 The retracted tool is fabricated in two steps. Firstly insulation using CVD
coating and it is followed by electrochemical etching.

 Copper tool of 300 µm diameter is cleaned using acetone and again it is


cleaned in a solution of ethylene glycol using ultrasonic cleaner for
efficient CVD coating.

 SiO2 is coated in the copper microtool using chemical vapour deposition.


SiO2 is deposited at 430 ⁰C in nitrogen and oxygen environment. After
coating coated tool is dried.

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EXPERIMENTATION contd.,

Electrochemical Micromachining parameters;

25
EXPERIMENTATION contd.,

Generated Taguchi Design of Experiments: (L9 Orthogonal Array)

26
EXPERIMENTATION contd.,

SCHEMATIC LAY-OUT OF EXPERIMENTAL PLAN:

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MICROHOLES IN COPPER SHEETS USING BARE TOOL

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MICROHOLES IN COPPER SHEETS USING COATED TOOL

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MICROHOLES IN COPPER SHEETS USING RETRACTED TOOL

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RESULTS AND DISCUSSION

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RESULTS AND DISCUSSION

Influence of bare tool on material removal rate


Increase in electrolyte concentration and voltage increases the MRR.

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RESULTS AND DISCUSSION

Influence of bare tool on Conicity:


 The increase in feed increases conicity.

33
RESULTS AND DISCUSSION

Influence of bare tool on overcut:


Overcut in bare tool is high due to many reasons like variation in
pulsed frequency, change in current density, stray current effect.

34
RESULTS AND DISCUSSION

Influence of coated tool on MRR:


Chromium coated tool increases MRR as the current density increases.

35
RESULTS AND DISCUSSION

Influence of coated tool on conicity:


The conicity in case of coated tool increases with thickness since
the current efficiency is high.

36
RESULTS AND DISCUSSION

Influence of coated tool on Overcut:


The coated tool increases the electric field concentration which narrows and
reduces overcut.

37
RESULTS AND DISCUSSION

Influence of retracted tool on MRR:


Etched tool decreases MRR when compared to bare and coated tool due to
large inter electrode gap.

38
RESULTS AND DISCUSSION

Influence of retracted tool on conicity:


The etched tool due to increase in feed rate reduces conicity as the tool contact area (surface) is
less and current efficiency will be higher in the machining domain.

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RESULTS AND DISCUSSION

Influence of retracted tool on overcut:


Overcut is reduced due to low stray current phenomenon and it is mainly
due to the reduction in current densities.

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RESULTS AND DISCUSSION

Influence of various tools on MRR:


Exp no vs MRR
0.3

0.25

0.2
MRR(mg/sec)

0.15 Bare
coated
0.1 retractive

0.05

0
0 2 4 6 8 10
Exp No.

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RESULTS AND DISCUSSION

Influence of various tools on Overcut:


Exp no vs overcut
1

0.9

0.8

0.7
Overcut (mm)

0.6

0.5 bare

0.4 coated
retractive
0.3

0.2

0.1

0
0 2 4 6 8 10
Exp No.

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CONCLUSION

 For increased material removal rate of coated tool can be preferred but it
results in overcut. Increase in material removal rate of 2.16 times in case of
bare tool and 1.25 times the etched tool.

 Insulated tool is optimal for better material removal rate and machining
microhole profile.

 Retracted tip tool produces minimum overcut micro holes with good
accuracy and high aspect ratio.

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FUTURE WORK

 The surface integrity studies of the work piece can be studied


for machined samples of three different tools and wear
behavior in tools.

 The modeling of three different tools with respect to material


removal rate and overcut can be developed.

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REFERENCES

1. Sandip anasane.S, Bhattacharya.B,.(2016). “Experimental Investigation on


Suitability of electrolytes for electrochemical machining of titanium”. International
Journal of Advanced Manufacturing and Technology.
2. Ghoshal B, Bhattacharya.B (2015) “Generation of micro-features on stainless steel
by electrochemical micromachining”. International Journal of Advanced
Manufacturing and Technology. ( v76) , Pg.39-50.
3. Yong Liu, Cai H., et al., (2015)“Fabrication of micro spherical electrode by one
pulse EDM and their application in electrochemical micromachining ”. Journal of
Manufacturing Processes ( v17) , Pg.162-170.
4. Mithu M.A.H, Fantoni,G et al.,(2014).“How microtool dimension influences
electrochemical micromachining”. International Journal of Advanced
Manufacturing and Technology. ( v70) , Pg.1303-1312.
5. Spieser A,Ivanov A., (2013)“Recent developments and research challenges in
electrochemical micromachining”. International Journal of Advanced
Manufacturing and Technology,( v69) , Pg.563-581.

45
REFERENCES

6. Rajurkar,K,P, Sundaran M,M, Malshe A,P,(2013). “Review of Electrochemical and


Electrodischarge Machining”. Annals of CIRP ( v6) , Pg.513-26.
7. Swain A,K, Sundaram, M,M, Rajurkar, K,P, (2012) “Use of coated tools in
advanced manufacturing: A exploratory study in electrochemical machining
context”. Journal of Manufacturing Processes ( v14) , Pg.150-159.
8. Jain ,V.K, Kalia,S, et al.,(2012).“Fabrication of micro-features and micro-tools
using electrochemical micromachining”. Journal of Manufacturing Processes( v14)
Pg.150-159.
9. Yong Liu, Zhu D., et al.,(2011). “Development of microelectrodes for
electrochemical micromachining”. International Journal of Advanced
Manufacturing Technology ( v55) ,Pg.195-203.
10. Bhattacharyya,B., Malapati.M, Munda J, et al, (2007) “Influence of tool vibration
on machining performance in electrochemical micromachining of copper”.
International Journal of Machine Tools &Manufacture,( v47) , Pg.335-342.

46
REFERENCES

11. Zhou X.,Zhang, et al.,(2007).“Electrochemical micromachining of Nitinol by


confined etchant layer technique”. Journal of Electrochemica Acta, ( v52) ,
Pg.4191-4196.
12. Rajurkar,K.P, Levy,G et al.,(2006) “Micro and Nano Machining by Electro-Physical
and Chemical processes”. Annals of CIRP ( v55).
13. Bhattacharyya,B, Malapatti,M, Munda , J, (2005) “Experimental study on
electrochemical micromachining”. Journal of Materials Processing Technology
(v55) ,page no.485-492.
14. Bhattacharyya,B, Malapatti,M, Munda , J ,(2004) “Advancement in electrochemical
micro-machining”. International Journal of Machine Tools &Manufacture ( v44)
,page no.1577-1589.
15. Rajurkar,K.P, Mc Geough,J.A., et al., (1999).“New Developments in Electro-
chemical Machining”. Annals of the CIRP( v48).

47
REFERENCES

16. Liu Y, Zhu D, Zeng YB, Yu HB. Development of microelectrodes for


electrochemical micromachining. Int J Adv Manuf Technol 2011;55:195–203.

17.Liu GH, Li Y, Chen XP, Lv SJ. Research on side-insulation of tool electrode for
micro electrochemical machining. Adv Material Res 2009;60:386–9.

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THANK YOU

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