Electrochemical micro-machining of high aspect ratio micro-tools using quasi-solid electrolyte

Electrochemical micro-machining of high aspect ratio micro-tools using quasi-solid electrolyte With the outbreak of product miniaturization, there is an increasing demand for the fabrication of micro-tools in recent years. However, fabrication of accurate micro-tools with high aspect ratio is a great challenge for traditional processes due to their mechanical-thermal effects. Electrochemical micro-machining (EMM) has many advantages over other machining processes, which makes it a potential method to manufacture micro-tools. This paper proposes a novel EMM fabrication method of micro-tools with high aspect ratio, in which an agarose hydrogel of high intensity is employed as quasi-solid electrolyte. During the machining process, a tungsten rod is inserted into the quasi-solid electrolyte which is partially immersed into working electrolyte (2 mol/L NaOH solution) to maintain mass balance. The shapes of micro-tools fabricated in liquid electrolyte and quasi-solid electrolyte under same machining conditions are analyzed. Compared to liquid electrolyte, quasi-solid electrolyte has the advantages of improved precision and ability to manufacture high aspect ratio micro-tools. Besides, effects of main parameters, including vertical distance, duty factor, and pulse peak voltage, on the machining accuracy and efficiency are investigated experimentally. Finally, optimum parameters of 12 mm vertical distance, 50% duty factor, and 5 V pulse peak voltage are selected based on experiments. Using these parameters, a cylindrical micro-tool with an average diameter of 12 μm and aspect ratio of 408.33 is successfully fabricated. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png The International Journal of Advanced Manufacturing Technology Springer Journals

Electrochemical micro-machining of high aspect ratio micro-tools using quasi-solid electrolyte

Loading next page...
 
/lp/springer_journal/electrochemical-micro-machining-of-high-aspect-ratio-micro-tools-using-d6835TDUzr
Publisher
Springer London
Copyright
Copyright © 2017 by Springer-Verlag London
Subject
Engineering; Industrial and Production Engineering; Media Management; Mechanical Engineering; Computer-Aided Engineering (CAD, CAE) and Design
ISSN
0268-3768
eISSN
1433-3015
D.O.I.
10.1007/s00170-016-9900-x
Publisher site
See Article on Publisher Site

Abstract

With the outbreak of product miniaturization, there is an increasing demand for the fabrication of micro-tools in recent years. However, fabrication of accurate micro-tools with high aspect ratio is a great challenge for traditional processes due to their mechanical-thermal effects. Electrochemical micro-machining (EMM) has many advantages over other machining processes, which makes it a potential method to manufacture micro-tools. This paper proposes a novel EMM fabrication method of micro-tools with high aspect ratio, in which an agarose hydrogel of high intensity is employed as quasi-solid electrolyte. During the machining process, a tungsten rod is inserted into the quasi-solid electrolyte which is partially immersed into working electrolyte (2 mol/L NaOH solution) to maintain mass balance. The shapes of micro-tools fabricated in liquid electrolyte and quasi-solid electrolyte under same machining conditions are analyzed. Compared to liquid electrolyte, quasi-solid electrolyte has the advantages of improved precision and ability to manufacture high aspect ratio micro-tools. Besides, effects of main parameters, including vertical distance, duty factor, and pulse peak voltage, on the machining accuracy and efficiency are investigated experimentally. Finally, optimum parameters of 12 mm vertical distance, 50% duty factor, and 5 V pulse peak voltage are selected based on experiments. Using these parameters, a cylindrical micro-tool with an average diameter of 12 μm and aspect ratio of 408.33 is successfully fabricated.

Journal

The International Journal of Advanced Manufacturing TechnologySpringer Journals

Published: Jan 13, 2017

References

You’re reading a free preview. Subscribe to read the entire article.


DeepDyve is your
personal research library

It’s your single place to instantly
discover and read the research
that matters to you.

Enjoy affordable access to
over 12 million articles from more than
10,000 peer-reviewed journals.

All for just $49/month

Explore the DeepDyve Library

Unlimited reading

Read as many articles as you need. Full articles with original layout, charts and figures. Read online, from anywhere.

Stay up to date

Keep up with your field with Personalized Recommendations and Follow Journals to get automatic updates.

Organize your research

It’s easy to organize your research with our built-in tools.

Your journals are on DeepDyve

Read from thousands of the leading scholarly journals from SpringerNature, Elsevier, Wiley-Blackwell, Oxford University Press and more.

All the latest content is available, no embargo periods.

See the journals in your area

DeepDyve Freelancer

DeepDyve Pro

Price
FREE
$49/month

$360/year
Save searches from Google Scholar, PubMed
Create lists to organize your research
Export lists, citations
Read DeepDyve articles
Abstract access only
Unlimited access to over
18 million full-text articles
Print
20 pages/month
PDF Discount
20% off