Performance of Micro-Hole Drilling by Ultrasonic-Assisted Electro-Chemical Discharge Machining

Meifal Rusli; Katsushi Furutani

doi:10.4028/www.scientific.net/AMR.445.865

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HomeAdvanced Materials ResearchAdvanced Materials Research Vol. 445Performance of Micro-Hole Drilling by...

Performance of Micro-Hole Drilling by Ultrasonic-Assisted Electro-Chemical Discharge Machining

Abstract:

Electro-chemical discharge machining (ECDM) is one of nontraditional processes for micro-fabrication of non-conductive materials. A high applied voltage is preferable to form a gas film and to generate discharge in the film. However, accumulation of discharge heat often causes cracks of the surface because non-conductive materials have low heat conductivity. In this study, the effect of ultrasonic vibration and the electrolyte level on the performance of gravity-feed drilling by ECDM was investigated. Ultrasonic vibration was applied to a glass plate. A tungsten rod as a tool electrode was fed by gravity. Ultrasonic vibration changed the discharge behavior and improved electrolyte circulation. Although high amplitude ultrasonic vibration caused very dense and wide current pulses consistently during machining process, it decreased removal rate significantly. In addition, electrolyte levels affect single bubble size and the resistance in the electrolyte. Low electrolyte level will cause higher resistance, and higher temperature of the tool electrode and workpiece. A high bias current flew at a low electrolyte level without ultrasonic vibration. In this case, removal rate decreased and surface integrity was improved.

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Periodical:

Advanced Materials Research (Volume 445)

Pages:

865-870

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.445.865

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Online since:

January 2012

Authors:

Meifal Rusli, Katsushi Furutani

Keywords:

Gas Bubble, Glass, Pulse Density, Surface Integrity, Vibration Amplitude

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