Journal of Materials Processing Technology 169 (2005) 485–492

Experimental study on electrochemical micromachining

B. Bhattacharyya, M. Malapati, J. Munda
Department of Production Engineering, Jadavpur University, Kolkata, India

Received 14 June 2004; received in revised form 4 April 2005; accepted 8 April 2005

Abstract

Electrochemical micromachining (EMM) appears to be very promising as a future micromachining technique since in many areas of
applications it offers several advantages that include higher machining rate, better precision and control and a wide range of materials that
can be machined. Present paper will highlight the influence of various electrochemical micromachining parameters like machining voltage,
electrolyte concentration, pulse period and frequency on material removal rate, accuracy and surface finish in microscopic domain. According
to the present experimental study, the most effective values for micromachining parameters have been considered as 3 V machining voltage,
55 Hz frequency and 20 g/l electrolyte concentration that can enhance the accuracy with highest possible amount of material removal. It has
been observed through SEM micrographs that low voltage, moderate electrolyte concentration and high frequency can improve the accuracy
with lesser number of micro-sparks. Radial stray cut and on-line pulse pattern during generation of micro-sparks are also considered for
selecting the effective zone of EMM parameters. This research development made in this area of EMM will open up many challenging
possibilities for effective utilization of electrochemical material removal mechanism in the area of micro-manufacturing.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Micromachining; EMM; Machining parameters

1. Introduction
Micromachining refers to small amount of material
removal that ranges from 1 to 999 ␮m. Recent changes in
societies demand have forced us to introduce more and more
micro-parts into various types of industrial products. For
example, the fuel injection nozzle for automobiles, several
regulations arising from environmental problems have forced
manufacturers to improve the design of the nozzle towards
those of smaller, compact with high accuracy. Inspection of
internal organs of human body and surgery without pain are
universally desired. Miniaturization of medical tools is one
of the effective approaches to arrive at this target. Micro-
machining technology plays an increasing decisive role in
the miniaturization of components ranging from biomedical
applications to chemical micro-reactors and sensors. Slots,
complex surfaces and micro-holes used to be produced in
large numbers, sometimes in a single work piece, especially
in electronic industries. These things are performed by using
conventional machining techniques also, but the problems
E-mail address: bb13@rediffmail.com (B. Bhattacharyya).
generally faced are, such as tool wear, rigidity problem of the
tool, heat generation at the tool–work piece interface. Some-
times, it is difficulty to produce complex shapes by using
conventional techniques [1].
Non-traditional machining processes are getting their
importance due to its versatility and controlled parameters. In
non-conventional machining, most of the processes are ther-
mal oriented, e.g. Electro discharge machining (EDM), laser
beam machining (LBM), Electron beam machining (EBM),
etc., which may cause thermal distortion of the machined sur-
face. Chemical machining and Electrochemical machining
are thermal free processes, but chemical machining cannot be
controlled properly in this micromachining domain [2]. Elec-
trochemical micromachining (EMM) appears to be a very
promising micromachining technology due to its advantages
that include high MRR, better precision and control, rapid
machining time and environmentally acceptable and it also
permits machining of chemically resistant materials like tita-
nium, copper alloys, super alloys and stainless steel, which
are widely used in biomedical, electronic and MEMS applica-
tions [3–5]. Gusseff first patented electrochemical machining
(ECM) in 1929. But electrochemical machining was intro-

0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2005.04.074
486 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492
duced in the early 1960s in aerospace industries for shaping,
finishing of larger parts. ECM machining process is applied to
the micromachining range of applications for manufacturing
of ultra precision shapes; it is called electrochemical micro-
machining. EMM is an effective method of producing variety
of components for the aerospace, automotive, defense, elec-
tronic and biomedical industries. Attempts have already been
made to develop an EMM experimental set up and carrying
out pilot experimentation for achieving satisfactory control
of EMM process parameters to meet the micromachining
requirements [6]. A better understanding of the high-rate
dissolution is urgently required for EMM to become widely
employed manufacturing process in the micro-manufacturing
domain [7]. Although research institute and researchers have
already initiated some research in this area of machining, it
still requires lot of research. However, to exploit full poten-
tial of EMM, in depth research is needed to improve the
material removal, surface quality and accuracy by optimiz-
ing the various EMM process parameters. Keeping in view
of these requirements, experimental set up has been devel-
oped to achieve precise micro-tool motion for investigating
the influence of various major process characteristics, such
as machining voltage, electrolyte concentration, frequency,
pulse period, pulse on–off-time and micro-tool feed rate on
the material removal and accuracy. Radial stray current effect
and micro-sparks phenomena are also been considered for
deriving most suitable process parameters.
2. Major characteristics of EMM
EMM offers several advantages as compared to chemical
micromachining (CMM), such as higher unit removal, use
of ecologically safe etchant, faster rate of material removal
and machining of chemically resistant materials, i.e. titanium,
super alloys and stainless steel, etc. The influence of cur-
rent density, current distribution, anodic reactions and mass
transport effects on unit removal and accuracy is very cru-
cial. The shape of feature to be generated and its dimension
depends not only on the dimensional features like micro-tool
electrode and inter electrode gap (IEG) but also on position
features, such as electrolyte flow direction, machining volt-
age and hydrodynamic conditions [8]. In order to achieve the
effective and efficient micromachining, the role of following
major EMM characteristics are to be investigated thoroughly
through planned experimental study.
2.1. Role of power supply
Generally the nature of the power supply is either DC full
wave rectified or pulsed DC. A full wave rectified DC supplies
continuous voltage, where the current efficiency depends on
the current density. Decrease in current density decreases the
current efficiency, which can improve the surface finish and
accuracy of form of the work piece. In pulsed DC, current
efficiency is much more dependent on current density [9]. In
order to achieve proper EMM, the current density is main-
tained as low and operating voltages of less than 5 V are
required. If the current density and the voltage is high, con-
centration of reaction products are high and these reaction
products cannot be removed properly due to narrow small
inter electrode gap. The increasing contaminations of reac-
tion products are caused to deposit in-between micro-tool
and work piece, so that the work piece material no longer
dissolves properly [10]. Furthermore, change in electrolyte
concentration and temperature increases the electrical resis-
tivity, which in turn affects the accuracy. For improving shape
accuracy and finish, the IEG should be kept as small as possi-
ble. The small IEG is limited by the generation of unwanted
electrical discharges, which can reduces the surface quality,
accuracy and surface finish. High off-time ultra short pulses
improve the localization of dissolution to sub-micrometer,
i.e. enhance the accuracy. The anodic electrochemical dis-
solution occurs during the ultra short pulse on-time and the
dissolved products, i.e. sludge, gas bubbles and heat can be
flushed away from the inter electrode gap completely by the
flow of electrolyte during pulse off-time. Pulses are used in
the form of single pulses or multiple/group pulses to achieve
necessary accuracy in the micromachining. Group pulses are
preferred because of its ability to achieve the required dimen-
sion quickly with higher accuracy. For improving accuracy
and surface finish, short pulse voltage with high off-time is
preferred. 3D-micromachining is also achieved by the appli-
cation of ultra short voltage pulses [11–13]. The accuracy can
be improved by the application of high off-time ultra short
pulse DC power supply.
2.2. Role of electrolyte
The electrolyte not only completes the electric circuit
between the tool and work piece, but also allows the desired
machining reactions to occur. Electrolyte must possess less
throwing power apart from basic properties to increase the
machining accuracy. EMM electrolytes are basically classi-
fied into two categories, such as passive electrolytes contain-
ing oxidizing anions, i.e. sodium nitrate (NaNO3 ), sodium
chlorate, etc., and non-passive electrolytes containing aggres-
sive anions, i.e. sodium chloride. Passive electrolytes are
known to give better machining precision. This is due to
formation of oxide films and oxygen evolution in the stray
current region. It is usual to work with NaNO3 (pH 7) that
can improve the dissolution of material without affecting the
micro-tool. However, acidic electrolytes are advantageous
due to formation of soluble reaction products, which can com-
pletely swept clean from the narrow IEG during machining
without micro-tool being affected. By decreasing the elec-
trolyte concentration, inter electrode gap can be reduced to
a lower value for improving the micromachining efficiency.
Additive chemicals, gas mixed electrolyte, acidic electrolyte,
hot electrolyte, etc., are preferred to achieve better dimen-
sional accuracy. Addition of additive chemicals like NaHSO4
to the electrolyte to reduce the concentration of dissolved
 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492
reaction products that in turn improve the accurate shape
generation. Machining reactions can speeds up by using hot
electrolytes too, that reduces the requirement of over volt-
ages. Most of the researchers recommended the NaClO3 ,
NaNO3 and NaCl electrolyte solution with different concen-
trations for EMM.
2.3. Role of inter electrode gap
For accurate EMM shape generation, the IEG control plays
a vital role. If the inter electrode gap is kept to a small value,
i.e. 10–50 ␮m, the resolution of machined shape becomes
better and the possibility of applying ECM to micromachin-
ing increases, and it can also increases the shape accuracy
and unit removal [6,14]. In EMM, the IEG can be reduced
to several microns by lowering the machining voltage and
electrolyte concentration [15]. For reducing non-uniformity
in the electrolyte conductivity, which is significant for disso-
lution process, a more stable IEG is necessary. Maintaining
the stable stage of IEG uniformly is an important requirement
in EMM for achieving high accuracy and surface finish.
2.4. Role of micro-tool
The accuracy of the micro-tool shape and surface fin-
ish directly affects the work piece accuracy. The micro-tool
materials should have good thermal and electrical conduc-
tivity, corrosive resistant and high machinability, stiffness
to withstand electrolyte pressure without vibration and less
stray current effect. Suitable materials for micro-tool are plat-
inum, tungsten, titanium, stainless steel and molybdenum.
However, micro-tool material selection mainly depends on
electrochemical and mechanical properties, shape to be pro-
duced and material of the work piece. For achieving higher
accuracy, insulated micro-tool, dual pole tool, etc., are pre-
ferred. In dual pole tool, the insulated micro-tool is covered
with anodic metal bush to enhance the accuracy. For reducing
the effect of stray current, the micro-tool should be insulated
properly so that current flows only through the front face,
which in turn causes less side gap [16]. Insulated materials
like SiC, Si3 N4 can be coated on the side wall of the micro-
tool by chemical vapour deposition (CVD) process.
2.5. Role of micro-spark generation
In EMM, micro-sparks are generated at higher machining
voltage and at lower electrolyte concentration due to small
narrow IEG, which can adversely affect the accuracy and
surface finish of the machined micro-hole. Micro-tool feed
rate should be maintained above the material removal rate
to avoid micro-spark generation. Reduction in IEG increases
the unwanted electrical discharges that may cause for short
circuit. These short circuits reduce the accuracy and sur-
face finish of the work piece and lead to electro-erosion of
the micro-tool. At narrow machining zone of EMM, Joule
heating, generation of hydrogen and subsequent breaking of
487
hydrogen due to high voltage may cause onset of unwanted
electrical discharges. These draw backs can be controlled by
selecting optimal parametric combination through optimiz-
ing the values of IEG, electrolyte concentration, voltage and
pulse period, etc.
3. Experimental planning
Keeping in view of the present research objectives, exper-
imental investigation and analysis has been carried out in dif-
ferent parametric combinations, for deriving effective para-
metric combination, which can be useful for achieving better
micromachining. To analyze the influence of the desired per-
formance characteristics on material removal and machining
accuracy, proper scheme has been designed with the uti-
lization of developed EMM experimental set up, which is
shown in Fig. 1. The EMM experimental set up consists
of mechanical machining unit, electrolyte flow system and
power supply unit that includes microprocessor control unit
and stepper motor control unit. The microprocessor pro-
grammes are so developed to control the micro-tool move-
ment as per the micromachining requirements. Three types
of micro-tools have been chosen for the experimentation, i.e.
Ø 275 ␮m platinum tool, Ø 596 ␮m stainless steel tool and
Ø 357 ␮m stainless steel tool. The work piece specimens
are 15 mm × 10 mm × 0.15 mm maskless copper plates. The
electrolyte used for experimentation is fresh aqueous solution
of sodium nitrate having different concentrations. Variable
rectangular DC pulsed supply has been used for experimen-
tation. The unit removal (UR), which is defined as material
removed per pulse or material removal per unite time and
accuracy have been measured for set of experiments with var-
ious combinations of process parameters. Applied machining
voltages of 3, 5 and 7 V have been selected for experiments.
Electrolyte concentrations of 10, 20 and 30 g/l have been cho-
sen for experiments. Frequency of pulsed power supply of
35, 45 and 55 Hz has also been considered for various exper-
iments. Machining accuracy is measured with the help of
side gap. The side gap phenomena of the machined work
piece have been observed with the help of measuring micro-
scope (Olympus, Japan). Values of various parameters are
measured with the help of digital storage oscilloscope (DL
1520 Yokogawa, Japan), pH meter (Mettler Toledo, Switzer-
land), Multimeter (TX3 Tektronix, USA), Precision weighing
machine (Mettler Toledo, Switzerland) and precision stop-
watch (Baker, India). Unit removal is calculated as the mate-
rial removed, i.e. the difference of initial and final weight of
the work piece, per unit time. Digital storage oscilloscope
has been utilized for on-line observation of the voltage pulse
pattern during micromachining operation. The analysis of
the stored pulse patterns has been carried out with the help
of waveform viewer software (Yokogawa, Japan) for investi-
gating the causes of the onset of micro-sparks during various
sets of micromachining experiments. For studying the effects
of various predominant process parameters on the shape
488 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492

Fig. 1. Photographic view of the experimental EMM set up.

accuracy, micromachined holes have been viewed through gap. An attempt has also been made to find out an optimal
scanning electron microscopy (SEM), and SEM micrographs combination of EMM parameters for effective and efficient
are further analyzed. micromachining.

4.1. Influence of machining parameters on unit removal

4. Experimental results and discussions
Experiments have been carried out on the developed EMM
experimental set up to predict the influence of the predom-
inant process characteristics, i.e. machining voltage, elec-
trolyte concentration, frequency of pulsed power supply,
micro-tool feed rate, etc., on unit removal and side gap. Exper-
imental results are plotted in the form of graphs to exhibit
the influence of different process parameters on UR and side
It is observed from previous experiments that the highest
amount UR is achievable at 30 g/l electrolyte concentration.
Hence, influence of machining voltage on UR is experimen-
tally observed at 30 g/l concentration as shown in Fig. 2
and keeping other parametric conditions same. It has been
observed from Fig. 2 that the UR increases with voltage and
frequency at all the set of parametric combinations. Due to
the increase in machining voltage and frequency machining

Fig. 2. Influence of machining voltage on unit removal.

 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492
Fig. 3. SEM micrographs of machined micro-holes at different parametric conditions: (a) 3 V, 45 Hz and 30 g/l; (b) 7 V, 45 Hz and 30 g/l; (c) 3 V, 55 Hz and
30 g/l.
current increases that leads to increase in current density.
According to Faraday’s law, material removal is directly pro-
portional to the machining current. However, Faraday’s law
is slightly deviated due to small narrow IEG, i.e. 5–15 ␮m,
where polarization voltage is not constant, and it may lead
to non-uniform UR. Hence, Faraday’s law cannot be applied
directly in the micromachining without considering the value
of the IEG. In 55 Hz frequency, UR increases slowly from 3 to
5 V as compared to other combinations. Increase in machin-
ing voltage leads to high dissolution rate, i.e. unit removal.
The figure represents the chances of overtaking the curves
each other slightly due to the occurrence of shortcomings
during experiments, e.g. micro-sparks, improper electrolyte
flow and other constraints in the mechanical unit.
Fig. 3(a) exhibits the SEM micrograph of a machined
micro-hole at a particular parametric condition, i.e. 3 V
machining voltage, 45 Hz frequency, 30 g/l electrolyte con-
centration, 0.144 mm/min feed rate and pulse on–off ratio
of 2:1. In this condition, unit removal is less and stray cur-
rent effect also low. Small irregularities can be observed
at the circumference of the machined micro-hole from the
micrograph. These irregularities are caused by the genera-
tion of micro-sparks. At this low parametric condition, i.e.
3 V, 45 Hz and 30 g/l, unit removal is less than the micro-tool
feed rate and leads to increase chances of contact between
micro-tool and job, which generates micro-sparks initially,
and finally, it tends towards short circuit. At higher paramet-
ric condition, i.e. 7 V machining voltage, 45 Hz frequency,
30 g/l electrolyte concentration, 0.144 mm/min feed rate and
pulse on–off ratio of 2:1, higher stray current affected area and
irregularities like pitting are observed in work piece machined
surface as shown in Fig. 3(b). Higher voltage and higher elec-
trolyte concentration increases the dissolution process and it
generate larger amount of hydrogen. This hydrogen bubbles
disrupt the electrolyte flow in the narrow IEG, due to for-
mation of cavitations at higher voltage and frequency, cause
the onset of micro-sparks. These micro-sparks increase mate-
rial removal from the larger job surface. Fig. 3(c) exhibits the
SEM micrograph at a particular parametric condition, i.e. 3 V
machining voltage, 55 Hz frequency, 30 g/l electrolyte con-
centration, 0.144 mm/min feed rate and pulse on–off ratio
of 2:1 that produces higher shape accuracy, i.e. less stray
current affected area and irregularities and maximum pos-
sible amount of unit removal. From the micrograph, it is
observed that a little amount of stray current effect, which is
489
due to lower machining voltage though concentration of elec-
trolyte is as the previous machining combination. At higher
electrolyte concentration, variable local current distribution
results in stray current effect. Reducing the electrolyte con-
centration eliminates this type of effect. Again, the higher
accuracy of the machined micro-hole has been observed
because of higher frequency. At higher frequency, number
of pulse off-time increases which helps to remove machined
products from IEG results in controlled machining, which
improves accuracy.
4.2. Influence of machining parameters on accuracy
Fig. 4 shows the influence of machining voltage on side
gap. From graph, it is noted that in 35 Hz frequencies, the
side gap is almost same and slightly varied for different
voltages, i.e. 3, 5 and 7 V. In 55 Hz frequencies condition,
side gap increases almost linear with higher slope with volt-
age and in case of 45 Hz frequencies, side gap is increased
slightly from 3 to 5 V, after that it rapidly increased. Due to
the increase of machining voltage, the localization effect of
current flux flow decreases. Stray current flow increases in
the machining zone due to the poor localization effect, in
turn affecting the more material removal from the larger sur-
face area of the work piece, which cause the increment in
side gap. The side gap is also due to generation of micro-
sparks. In higher voltage and frequencies, electrochemical
reactions generate hydrogen gas bubbles and those bub-
bles breakdown resulting in the occurrence of micro-sparks.
This sparking causes uncontrollable material removal in the
larger area of work piece which in turn produces larger side
gap.
Fig. 5 shows the effect of machining voltage and frequency
on accuracy and surface integrity in the form of stray current
affected area at a particular parametric condition, i.e. 30 g/l
electrolyte concentration, 0.144 mm/min feed rate and pulse
on–off ratio of 2:1. In 30 g/l electrolyte concentration, stray
current effect on machined surface is more predominant. Feed
rate is selected as low as possible to achieve higher accuracy
and surface finish. Pulse period in the ratio of 2:1, increases
unit removal. From graph, it is noted that the radial stray
current affected area, i.e. radial stray cut is increased with
increase in frequency. Increase in frequency causes reduc-
tion in pulse period and number of pulses is increased. The
average pulse on time is increased because it is twice the off-
490 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492

Fig. 4. Influence of machining voltage on side gap.

time. Due to the increment in average on time period during
machining effect of localization of electrochemical dissolu-
tion reduces, which in turn increases the larger area of stray
current effect. In high frequency, number of short pulses is
more and pulse off-time is less, i.e. half of the on time, to
remove the reaction products. All the reaction products are
not removed within the short span of off-time. These reaction
products stuck in-between job and micro-tool during pulse on
time and cause the onset of micro-sparks generation and it
finally tends towards larger area of material removal. In 35 Hz
condition, line representing 5 and 7 V is showing higher radial
stray cut, which is due to micro-sparks. In 45 Hz, 3 V condi-
tion, higher radial stray cut area has been observed compared
to 5 V. In 3 V and 45 Hz, linear material removal is low and it
falls beyond the micro-tool feed rate sometimes and causes
the onset of micro-spark, which results in larger area of mate-
rial removal.
4.3. Effect of micro-sparks phenomena on machining
accuracy
EMM machining accuracy, i.e. dimension, shape, surface
finish and surface integrity will be influenced by the occur-
rence of micro-sparks in the narrow micromachining zone,
which may not be possible to eliminate completely through
the existing EMM set up. These sparks are occurring due
to the variation in the machining parameters apart from tool
feed rate, accumulation of sludge and gas bubbles in the very
small inter electrode gap, etc. Fig. 6 shows the nature of
pulse pattern during the onset of micro-sparks phenomena

Fig. 5. Influence of machining voltage on radial stray cut.

 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492
Fig. 6. On-line pulse pattern during micro-sparks at 7 V, 55 Hz and 20 g/l.
during micromachining. Some of the reasons, which cause
the occurrence of micro-sparks are observed and monitored
during experimentation are enumerated below.
4.3.1. Micro-tool feed rate
Micro-tool feed rate should be always less than the linear
material removal rate, for performing effective microma-
chining. For the present set of experiments, the feed rate is
maintained constant, i.e. 0.144 mm/min, for different combi-
nations of machining parameters like frequency, machining
voltage and electrolyte concentration. Machining performed
with higher rate of parameter setting, i.e. 55 Hz frequency,
7 V machining voltage and 30 g/l of electrolyte concentration
produces higher linear material removal rate, i.e. higher
than the present micro-tool feed rate. This increases the
chances of onset of micro-sparks initially and finally, it
tends towards short circuit. But with 35 Hz frequency, 3 V
machining voltage, 10 g/l of electrolyte concentration, linear
material removal rate is drastically reduced and fall beyond
the micro-tool feed rate. When the process parameters are
reduced to a lower value, the possibilities of micro-sparks
in the existing experimental procedure, i.e. constant tool
feed rate might be reduced to a grater extent. Selection of
suitable tool feed rate will reduce the chance of occurrence
of micro-sparks. Further experiments are to be carried out
491
for finding out most optimal value of micro-tool feed rate at
different parametric combinations.
4.3.2. Electrolyte flow
Improper flow of electrolyte will also result in micro-
sparks. During micromachining, the hydrogen gas generation
and evaporation of water in the small IEG due to heating
increase the electrolyte concentration and viscosity. The high
concentrated viscous electrolyte is not able to remove all the
reaction products from the narrow machining zone. Hydro-
dynamic disturbance due to change in viscosity affects the
distribution for diffusion layer thickness on the micromachin-
ing zone, which influence the electrochemical dissolution
process to a great extent. There is a possibility of forming
reaction products in-between micro-tool and work piece that
result in the generation of micro-sparks and short circuit-
ing. Low-pressure electrolyte jet from two nozzles directing
the flow of the electrolyte just to the micromachining zone
was utilized for the present set of experiments. This type of
micro-sparks can be avoided by using only fresh electrolyte
with effective flow path design.
4.3.3. Inter electrode gap
In EMM, the IEG should be maintained very small and nar-
row for achieving higher machining accuracy in the microma-
chining domain. The IEG should be maintained in the range
of 5–15 ␮m for effective micromachining operation. Reac-
tion products that are formed during machining are removed
from IEG by means of low-pressure electrolyte jet. During
this process, there be possibility of sticking reaction prod-
ucts in-between micro-tool and work piece, which cause for
generation of micro-sparks. These sparks could be reduced
by using acidic electrolyte and vibration of the micro-tool.
Acidic electrolyte does not produce any insoluble reaction
products during machining. Piezoelectric transducer (PZT)
is used for vibrating micro-tools, which can enhance the end
gap during pulse off-time that will result in reduction or elim-
ination of micro-sparks generation.
Fig. 6 shows pulsed voltage fluctuation during micro-spark
generation at a condition of 7 V machining voltage, 55 Hz
frequency and 20 g/l electrolyte concentration. It shows the
nature of DC pulsed voltage during micromachining oper-
ation obtained from high-speed digital storage oscilloscope
and further analyzed with the help of Wave Form software.
Fig. 6 also shows the occurrence of micro-sparking during
machining and the influence of it on the voltage pulse in
larger scale (zoom). From figure, it has been observed that the
sparks are less. In this condition, linear material removal rate
is higher than tool feed rate 0.144 mm/min. However, some
sparks occur during machining due to hydrogen gas bubble
formation. In high voltage and frequency, machining reac-
tions are more and it can generate large amount of hydrogen
gas, these hydrogen gas bubbles breaks up at high voltage and
causes the onset of sparking. From SEM micrograph (Fig. 7),
it is clearly visible that the effect of stray current and spark-
ing, which leads to uneven material removal and irregularities
492 B. Bhattacharyya et al. / Journal of Materials Processing Technology 169 (2005) 485–492
Fig. 7. SEM micrograph of machined micro-hole at a particular parametric
condition, i.e. 7 V, 55 Hz and 20 g/l.
in the edge surface at high parametric combination, i.e. 7 V,
55 Hz and 20 g/l. The edge of the machined micro-hole is
uneven and not smooth due to the generation of micro-sparks
during machining.
5. Conclusions
Process parameters, such as micro-tool feed rate, elec-
trolyte flow, pulse period and pulse on–off ratio have been
successfully maintained at the desired values during all sets of
experiments. Experimental study is successfully conducted
on the developed EMM system to know the influence of
predominant process parameters on material removal and
accuracy. Process parameters like applied machining volt-
age, electrolyte concentration and frequency have significant
effect on UR and accuracy. UR increases with the increase
of electrolyte concentration, applied machining voltage and
frequency, but the increment of unit removal detoriates the
accuracy of the product. It is observed from the experimental
analysis that at higher frequency, medium concentrated elec-
trolyte and average machining voltage, i.e. 55 Hz, 20 g/l and
3 V, respectively, the desired accuracy can be achieved with
highest possible amount of material removal. It is evitable
from SEM micrographs that higher accuracy at moderate
material removal is achieved through short machining volt-
age pulses, i.e. at 55 Hz frequency of machining voltage. The
detail analysis of micro-sparks phenomena in the machining
gap with the help of digital storage oscilloscope and wave-
form viewer software, and various SEM micrographs of the
machined micro-holes establish the fact that the selection
of optimal parametric setting is essential to achieve higher
machining accuracy and better surface integrity of the micro-
machined products.
The research activities on electrochemical micromachin-
ing will open up many challenging possibilities for effective
utilization of electrochemical material removal mechanism in
micromanufacturing. The ultra short pulses also significantly
increase the machining accuracy. High off-time group pulses
are recommended for enhancing the accuracy and surface
finish. However, this area of research still requires further
investigation for better control of the EMM system during
machining operation, i.e. precise control of inter electrode
gap and micro-tool feed rate. This experimentation can be fur-
ther improved by eliminating some of the shortcomings like
generation of micro-sparks, precise motion of the work piece,
proper design of electrolyte flow path and proper coating of
micro-tools, etc. Finally, the research in the area of micro-
machining will be an important substitution and will fulfill
various urgent needs of the modern electronic and related pre-
cision industries especially in the area of microfabrication and
micromanufacturing. Hence, the present experimental values
and subsequent discussions and analysis of EMM process
characteristics will provide the basic incite to the researchers
for working in the area of micromachining and precision man-
ufacturing industries.
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