DESIGN OF AN ELECTROCHEMICAL CELL FOR MICROMACHINING APPLICATIONS

Issue title: MANUFACTURING AND DESIGN

Article type: Research Article

Authors: Bonifas, Alan | Lilly, Blaine

Affiliations: Faraday Technology, Inc., Clayton, OH 45315, U.S.A. | Department of Industrial, Welding and Systems Engineering, The Ohio State University, Columbus, OH 43210, U.S.A.

Abstract: Electrochemical machining is known to possess certain advantages for micromachining applications, among them very low tool deflection, and zero tool wear. However, dimensional precision is a potential drawback for this technology. Here we describe the development of a three-axis pulsed ECM machine designed specifically for machining features with dimensions less than one millimeter. Preliminary tests show that the machine is able to machine grooves in pure nickel substrates, using a 3M NaNO_3 electrolyte. The effects of electrolyte concentration, tool traversing speed, machining gap, and process parameters on metal removal and edge quality are presented.

Keywords: Electrochemical machining, micromachining, microscale machining

Journal: Journal of Integrated Design & Process Science, vol. 7, no. 1, pp. 1-23, 2003