Micro Tool Fabrications through Electrochemical Spark Machining Process

Abstract

 This article investigates the feasibility of producing an in-situ micro tool rod using micro-electrochemical spark machining (µ-ECSM) technology. The study included the examination of both electrical factors (such as voltage and duty factor) and non-electrical factors (such as electrolyte concentration and spindle speed) as the input parameters for the machining process. The responses measured in the study were the reduction in tool diameter and the surface roughness of the micro tool produced. The potassium hydroxide solution is used as a working fluid. The results indicate that voltage is the most crucial factor that influences micro tool fabrication. The utmost reduction in tool diameter, measuring 279.5 µm, occurred when utilizing machining parameters of 35V, 30%, 4 wt.%, and 600 rpm. Meanwhile, the lowest surface roughness for the micro tool was 3.42 µm, achieved with machining parameters of 35V, 10%, 4 wt.%, and 600 rpm. Additionally, the impact of machining settings on the micro tool electrode is covered.