Micromachining with ECDM: Research Potentials and Experimental Investigations
Electro Chemical Discharge Machining (ECDM) is an
emerging hybrid machining process used in precision machining of hard and brittle non-conducting materials. The present paper gives a
critical review on materials machined by ECDM under the prevailing machining conditions; capability indicators of the process are
reported. Some results obtained while performing experiments in micro-channeling on soda lime glass using ECDM are also presented. In these experiments, Tool Wear (TW) and Material Removal (MR)
were studied using design of experiments and L–4 orthogonal array. Experimental results showed that the applied voltage was the most influencing parameter in both MR and TW studies. Field
emission scanning electron microscopy (FESEM) results obtained on the microchannels confirmed the presence of micro-cracks, primarily responsible for MR. Chemical etching was also seen along the edges.
The Energy dispersive spectroscopy (EDS) results were used to detect the elements present in the debris and specimens.
[1] Allesu K., Ghosh A., "Preliminary qualitative approach of a proposed
mechanism of material removal in electrical machining of glass",
European Journal of Mechanical Engineering, 36, 1992, 202-207.
[2] R. Wuthrich, V. Fascio, "Machining of non-conducting materials using
ECDM phenomenon - an Overview", International Journal of Machine
Tools and Manufacturing", 45, 2005, 1095-1108.
[3] Yang C.T., S. S. Ho, Yan. B. H., "Micro-hole machining of borosilicate
glass through ECDM", Key Engineering Materials, 196, 2001, 149-166.
[4] Jain V. K., Singh Manoj, Agarwal D. C., Sidpara Ajay, "Investigation into machining of alumina ceramics using ECSM process", Global
Trends and Challenges in Design and Manufacturing, In proceedings of AIMTDR international conference, India, 2010, 235-240.
[5] Liu J. W., Yue T. M, Guo Z. N., "An analysis of the discharge mechanism in ECDM of particulate reinforced MMC", International Journal of Machine Tool and Manufacturing, 50, 2010, 86-96.
[6] Fascio V., Wuthrich R., Bleuler. H., "Spark assisted chemical engraving
in the light of electrochemistry", Electrochimica Acta, 49, 2004, 3997-4003.
[7] Cheng Chih-Pin, Wu Kun-Ling, Mai Chao-Chuang, Yang Cheng
Kuang, Hsu Yu-Shan, Yan Biing Hwa, "Study of gas film quality in
ECDM", International Journal of Machine Tools and Manufacture, 50,
2010, 689-697.
[8] Cao Xuan Doan, Kim Bo Hyun, Chu Chong Nam, "Micro-structuring of
glass with features less than 100 ╬╝m by ECDM", Precision Engineering,
33, 2009, 459-465.
[9] Kim Dae-Jin, Ahn Yoomin, Lee Seoung-Hwan, Kim Yong-Kweon,
"Voltage pulse frequency and duty ratio effects in an electrochemical
discharge micro-drilling process of pyrex glass", International Journal of
Machine Tools and Manufacture, 46, 2006, 1064-1067.
Yang C. T., Song S. L., Yan B. H., "Improving machine performance of
Wire ECDM by adding SiC abrasives to electrolyte", International
Journal of Machine Tools and Manufacture, 46, 2006, 2044-50.
[10] Jain V. K., Dixit P. M., Pandey P. M., "On the analysis of
electrochemical spark machining process", International Journal of
Machine Tools and Manufacture, 39, 1999, 165-186.
[11] Bhondwe K. L., Yadava V., Kathiresan G., "Finite element prediction of
material removal rate due to electrochemical spark machining",
International Journal of Machine Tools and Manufacture, 46, 2006,
1699-1706.
[12] Jain V. K., Choudhury S. K., Ramesh K. M., "On the machining of
alumina and glass", International Journal of Machine Tools and
Manufacture", 42, 2002, 1269-1276.
[13] Gautam N., Jain V. K., "Experimental investigations into ECSD process
using various tool kinematics", International Journal of Machine Tools
and Manufacture, 38, 1998, 15-27.
[14] Jain V. K., Chak S. K., "Electrochemical spark trepanning of alumina
and quartz", Machining Science and Technology, 4, 2000, 277-290.
[15] Jain V. K., Singh Manoj, Agarwal D. C., Sidpara Ajay, "Investigation into machining of alumina ceramics using ECSM process", Global
Trends and Challenges in Design and Manufacturing, In proceedings of
AIMTDR international conference, India, 2010, 235-240.
[16] Bhattacharya B, Doloi B. N., Sorkhel S. K., "Experimental Investigation
into EDM of Non Conductive Ceramic Materials", Journal of Material Processing Technology, 95, 1999, 145-154.
[17] Peng W. Y., Liao Y. S., "Study of ECDM for slicing non conductive
brittle materials", Journal of Material Processing Technology, 149,
2004, 363-369.
[18] Tandon S., Jain. V. K., Kumar P., Rajurkar K. P., "Investigations into
machining of composites", Precision Engineering, 12, 1990, 227-
238.
[19] Manna Alakesh, Narang Vivek, "A study on micro-machining of eglass-
fiber epoxy composite by ECSM process", Global Trends and
Challenges in Design and Manufacturing, in proceedings of AIMTDR
international conference, India, 2010, 395-400.
[20] Ranjit K. Roy, "A primer on the Taguchi Method", second edition,
2009, SME Publications.
[21] Jawalkar C. S., Sharma A. K., Pradeep Kumar, "Investigations on
ECDM of sodalime glass", M3-2011, International Conference, Singapore (Accepted)
[1] Allesu K., Ghosh A., "Preliminary qualitative approach of a proposed
mechanism of material removal in electrical machining of glass",
European Journal of Mechanical Engineering, 36, 1992, 202-207.
[2] R. Wuthrich, V. Fascio, "Machining of non-conducting materials using
ECDM phenomenon - an Overview", International Journal of Machine
Tools and Manufacturing", 45, 2005, 1095-1108.
[3] Yang C.T., S. S. Ho, Yan. B. H., "Micro-hole machining of borosilicate
glass through ECDM", Key Engineering Materials, 196, 2001, 149-166.
[4] Jain V. K., Singh Manoj, Agarwal D. C., Sidpara Ajay, "Investigation into machining of alumina ceramics using ECSM process", Global
Trends and Challenges in Design and Manufacturing, In proceedings of AIMTDR international conference, India, 2010, 235-240.
[5] Liu J. W., Yue T. M, Guo Z. N., "An analysis of the discharge mechanism in ECDM of particulate reinforced MMC", International Journal of Machine Tool and Manufacturing, 50, 2010, 86-96.
[6] Fascio V., Wuthrich R., Bleuler. H., "Spark assisted chemical engraving
in the light of electrochemistry", Electrochimica Acta, 49, 2004, 3997-4003.
[7] Cheng Chih-Pin, Wu Kun-Ling, Mai Chao-Chuang, Yang Cheng
Kuang, Hsu Yu-Shan, Yan Biing Hwa, "Study of gas film quality in
ECDM", International Journal of Machine Tools and Manufacture, 50,
2010, 689-697.
[8] Cao Xuan Doan, Kim Bo Hyun, Chu Chong Nam, "Micro-structuring of
glass with features less than 100 ╬╝m by ECDM", Precision Engineering,
33, 2009, 459-465.
[9] Kim Dae-Jin, Ahn Yoomin, Lee Seoung-Hwan, Kim Yong-Kweon,
"Voltage pulse frequency and duty ratio effects in an electrochemical
discharge micro-drilling process of pyrex glass", International Journal of
Machine Tools and Manufacture, 46, 2006, 1064-1067.
Yang C. T., Song S. L., Yan B. H., "Improving machine performance of
Wire ECDM by adding SiC abrasives to electrolyte", International
Journal of Machine Tools and Manufacture, 46, 2006, 2044-50.
[10] Jain V. K., Dixit P. M., Pandey P. M., "On the analysis of
electrochemical spark machining process", International Journal of
Machine Tools and Manufacture, 39, 1999, 165-186.
[11] Bhondwe K. L., Yadava V., Kathiresan G., "Finite element prediction of
material removal rate due to electrochemical spark machining",
International Journal of Machine Tools and Manufacture, 46, 2006,
1699-1706.
[12] Jain V. K., Choudhury S. K., Ramesh K. M., "On the machining of
alumina and glass", International Journal of Machine Tools and
Manufacture", 42, 2002, 1269-1276.
[13] Gautam N., Jain V. K., "Experimental investigations into ECSD process
using various tool kinematics", International Journal of Machine Tools
and Manufacture, 38, 1998, 15-27.
[14] Jain V. K., Chak S. K., "Electrochemical spark trepanning of alumina
and quartz", Machining Science and Technology, 4, 2000, 277-290.
[15] Jain V. K., Singh Manoj, Agarwal D. C., Sidpara Ajay, "Investigation into machining of alumina ceramics using ECSM process", Global
Trends and Challenges in Design and Manufacturing, In proceedings of
AIMTDR international conference, India, 2010, 235-240.
[16] Bhattacharya B, Doloi B. N., Sorkhel S. K., "Experimental Investigation
into EDM of Non Conductive Ceramic Materials", Journal of Material Processing Technology, 95, 1999, 145-154.
[17] Peng W. Y., Liao Y. S., "Study of ECDM for slicing non conductive
brittle materials", Journal of Material Processing Technology, 149,
2004, 363-369.
[18] Tandon S., Jain. V. K., Kumar P., Rajurkar K. P., "Investigations into
machining of composites", Precision Engineering, 12, 1990, 227-
238.
[19] Manna Alakesh, Narang Vivek, "A study on micro-machining of eglass-
fiber epoxy composite by ECSM process", Global Trends and
Challenges in Design and Manufacturing, in proceedings of AIMTDR
international conference, India, 2010, 395-400.
[20] Ranjit K. Roy, "A primer on the Taguchi Method", second edition,
2009, SME Publications.
[21] Jawalkar C. S., Sharma A. K., Pradeep Kumar, "Investigations on
ECDM of sodalime glass", M3-2011, International Conference, Singapore (Accepted)
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:57616", author = "C.S. Jawalkar and Apurbba Kumar Sharma and Pradeep Kumar", title = "Micromachining with ECDM: Research Potentials and Experimental Investigations", abstract = "Electro Chemical Discharge Machining (ECDM) is an
emerging hybrid machining process used in precision machining of hard and brittle non-conducting materials. The present paper gives a
critical review on materials machined by ECDM under the prevailing machining conditions; capability indicators of the process are
reported. Some results obtained while performing experiments in micro-channeling on soda lime glass using ECDM are also presented. In these experiments, Tool Wear (TW) and Material Removal (MR)
were studied using design of experiments and L–4 orthogonal array. Experimental results showed that the applied voltage was the most influencing parameter in both MR and TW studies. Field
emission scanning electron microscopy (FESEM) results obtained on the microchannels confirmed the presence of micro-cracks, primarily responsible for MR. Chemical etching was also seen along the edges.
The Energy dispersive spectroscopy (EDS) results were used to detect the elements present in the debris and specimens.", keywords = "ECDM, applied-voltage, FESEM, EDS.", volume = "6", number = "1", pages = "191-6", }
