Enhancing MRR and accuracy with magnetized graphite tool in electrochemical micromachining of copper

Abstract

Micro hole is the fundamental feature found in any device and its components. Hence this paper aims to produce the micro holes using electrochemical micromachining (EMM). The existing machining techniques in EMM for creating micro holes are associated with more overcut (OC). Hence, reducing OC and enhancing the machining rate (MR) is essential. This paper aspires to investigate the effect of the graphite electrode with magnetic force on the copper plate. Four different tools, namely the electromagnetic graphite tool (EMGT), permanent magnet graphite tool (PMGT), graphite tool, and stainless steel (SS) tool, are employed for these experiments. The major influencing factors are machining voltage in volts, duty cycle in % and electrolyte concentration in g/l was considered on MR and OC. The results revealed that EMGT, PMGT, and graphite electrodes produce MR of 106.4%, 74.6 % and 44.5 % over the SS tool at a parameter level of 23 g/l, 15 V, and 85%, respectively. Furthermore, graphite and EMGT electrodes resulted in 11.9% and 3.41% reduced OC, respectively, than the SS tool at parameter levels of 8 V, 95% and 28 g/l. Additionally, the scanning electron microscope (SEM) picture examination is conducted to identify the magnetic field effect on the work surface.