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Analysis of the side gap resulting from micro electrochemical machining with a tungsten wire and ultrashort voltage pulses

Hong Shik Shin1, Bo Hyun Kim2 and Chong Nam Chu1

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Micro wire electrochemical machining (ECM) using a Ø 10 µm tungsten wire as the tool electrode is presented. Since electrochemical machining does not wear out the tool, it can be easily applied to the fabrication of micro grooves by moving the tool electrode along a programmed toolpath. To minimize the side gap, ultrashort voltage pulses were applied between the tool electrode and the workpiece. Changes in the side gap according to the applied pulse voltage, pulse on-time and pulse period were investigated, and the optimal pulse condition for stable machining was obtained. By using this method, micro features such as micro grooves and gears were fabricated into stainless steel plates.


PACS

07.10.Cm Micromechanical devices and systems

85.85.+j Micro- and nano-electromechanical systems (MEMS/NEMS) and devices

81.40.Lm Deformation, plasticity, and creep

81.20.Wk Machining, milling

62.20.F- Deformation and plasticity

Subjects

Electronics and devices

Instrumentation and measurement

Condensed matter: structural, mechanical & thermal

Nanoscale science and low-D systems

Dates

Issue 7 (July 2008)

Received 18 January 2008, in final form 23 April 2008

Published 27 May 2008



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