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Electrochemical+micromachining+(emm)

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ElectroChemical MicroMachining

ElectroChemical MicroMachining

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  • 1. A Seminar on Electrochemical Micromachining (EMM) Presented by Todkar Mahesh S. M.Tech-I Manufacturing Engineering Under the Guidance of Dr. A Venugopal
  • 2. Non-Traditional Machining Need : • To machine newly developed metals and non-metals • To machine complex part geometries • To avoid surface damage
  • 3. Classification of Non-traditional Machining Processes This classification is carried out depending on nature of energy used for material removal: Mechanical Thermo- Chemical Electro- electric chemical • USM • EDM • CHM • ECG • AJM • EBM • PCM • EJD • WJM • LBM • AWJM • PAM • ECM
  • 4. Electrochemical Machining (ECM) • Reverse of electroplating • Work material must be a conductor • Material removal by anodic dissolution • Electrical energy + chemical energy
  • 5. Electrochemical Machining (ECM)
  • 6. Electrochemical Machining (ECM) Advantages over other Non-conventional Machining: • No thermal and mechanical stresses on the workpiece • No heat-affected layer on workpiece • No tool wear • Higher machining rate • Better precision • Controlled material removal • Wider range of materials can be machined • Utilized for removal and patterning of metal films and foils
  • 7. Electrochemical Machining (ECM) Applications: • Die sinking • Profiling and contouring • Trepanning • Micro-machining
  • 8. Electrochemical Micro-machining (EMM) Micromachining: • Material removal of small dimensions • Ranges from several microns to millimeters • For production of miniaturized parts and components Why Micromachining? • Difficulties in machining of miniature components and parts with conventional machining techniques • Requirement of precision manufacturing
  • 9. Electrochemical Micro-machining (EMM) Electrochemical Micro-machining: When electrochemical machining process is applied to micro-machining range (i.e. from 0.1 μm to 1 mm) for manufacturing ultra-precision shapes, it is called electrochemical micromachining(EMM).
  • 10. Electrochemical Micro-machining (EMM) Fundamental Observations: • Very small inter-electrode gap • Rate of dissolution (machining) depends on 1. Atomic weight ‘a’ 2. Valance ‘v’ of ion produced 3. Machining current ‘I’ 4. Time for which current passes • Shape of electrode remains unaltered
  • 11. Electrochemical Micro-machining (EMM) Metal Removal Method: MRR = Where, = current density, = metal dissolution efficiency, F = Faraday’s constant, Constant = Density of material, for = Valance of ion, particular = Atomic weight of ion. operation
  • 12. Electrochemical Micro-machining (EMM) MRR depends on: • Anodic reaction and Current efficiency( ), • Mass transport effects, • Current distribution( ) and Shape evolution.
  • 13. Electrochemical Micro-machining (EMM) Influence of various process characteristics: • Nature of power supply and Machining pulse 1. DC supply 2. Pulse DC supply • Inter-electrode gap • Electrolyte type, Concentration and Flow 1. Passivity Electrolyte 2. Non-Passivity Electrolyte • Size, shape and material of the Tool:
  • 14. Electrochemical Micro-machining (EMM) Sub-systems for EMM Setup: • Mechanical machine setup: Tool-feeding block Main machine body Work holding device
  • 15. Electrochemical Micro-machining (EMM) Sub-systems for EMM Setup: • Electrical power and control System:
  • 16. Electrochemical Micro-machining (EMM) Sub-systems for EMM Setup: • Electrolyte flow system: Job
  • 17. Electrochemical Micro-machining (EMM) • Experimental EMM setup:
  • 18. Electrochemical Micro-machining (EMM) Specifications of EMM setup: • Mechanical structure details: Base: (300 * 200 * 30) mm Vertical column: (300 * 50 * 20) mm Main Driving screw: Φ10 * 150L, 40 TPI, 50 mm thread Main screw nut: (25 * 50 * 40) mm, 40 TPI Main machining chamber: (100 * 200 * 80) mm³ Bearing: 10mm bore, 10 mm Thick
  • 19. Electrochemical Micro-machining (EMM) Specifications of EMM setup: • Stepper Motor Specifications: Step angle: 1.8° Step angle accuracy: 5% Holding torque: 40 N-cm Detent torque: 4 N-cm Weight: 0.5 kg
  • 20. Electrochemical Micro-machining (EMM) Specifications of EMM setup: • Pump Specifications: Power: 0.125 HP/ 0.09 kW Type: Centrifugal AC: 240 V Impeller Material: Teflon
  • 21. Electrochemical Micro-machining (EMM) Specifications of EMM setup: • Microprocessor: 8085 Intel® • Tool Specifications: Platinum, Φ 250 μm
  • 22. Electrochemical Micro-machining (EMM) Applications of EMM for Micro fabrication: • Nozzle plate for Ink Jet Printer Head • Production of High Accuracy Holes • 3D Micromachining
  • 23. Electrochemical Micro-machining (EMM) Recent Development in EMM: • Micro Electrochemical Milling • Wire Electrochemical Machining • Solid Electrochemical Machining • Oxide film laser lithography (OFLL) • Micro and Nanometer scaled surface structuring • Laser electrochemical micro machining (LECMM)
  • 24. Electrochemical Micro-machining (EMM) Conclusion: EMM setup • Successfully utilized • Fulfill the requirement and the need of Micromachining operations Areas of modifications: • Inter-electrode gap control feature • Precise control of machining parameters
  • 25. Thank you. Any Questions?