To adapt with today's rapidly changing world, fabrication of intricate microparts is becoming an urgent need. Manufacturing of these microparts with stringent requirements necessitates the early adoption of different microfabrication techniques. Wire electrochemical machining (WECM) is such a process which removes excess metal by dissolving it electrochemically. This process can easily generate features downscaled to micron ranges and offers several advantages like the requirement of very simple setup, fabrication of accurate complex microfeatures without undergoing any thermal stress, burr formation, and tool wear, which make it superior from other existing micromachining processes. However, this process is new, and little is known about its applicability and feasibility. Hence, the present work is directed towards developing suitable WECM setup to fabricate microfeatures by introducing proper means for enhancing the mass transport phenomenon. The tungsten tool wire for machining has been in situ etched to a diameter of 23.43 μm by a novel approach for retaining its regular cylindrical form and has been implemented during machining. Moreover, the influences of high duty ratio and applied frequency have been investigated on the corresponding width of the fabricated microslits and the experimental results have been represented graphically where the minimum width of the microslit is obtained as 44.85 μm. Furthermore, mathematical modeling has been developed to correlate duty ratio and applied frequency with generated slit width. Additionally, the mathematical modeling has been validated with practical results and complex stepped type microfeatures have been generated to establish process suitability.

References

References
1.
Bhattacharyya
,
B.
,
Malapati
,
M.
,
Munda
,
J.
, and
Sarkar
,
A.
,
2007
, “
Influence of Tool Vibration on Machining Performance in Electrochemical Micro-Machining of Copper
,”
Int. J. Mach. Tools Manuf.
,
47
(
2
), pp.
335
342
.
2.
Shin
,
H. S.
,
Kim
,
B. H.
, and
Chu
,
C. N.
,
2008
, “
Analysis of the Side Gap Resulting from Micro Electrochemical Machining With a Tungsten Wire and Ultrashort Voltage Pulses
,”
J. Micromech. Microeng.
,
18
(
7
), p. 075009.
3.
Bhattacharyya
,
B.
,
2015
,
Electrochemical Micromachining for Nanofabrication, MEMS and Nanotechnology
, Elsevier, Cambridge, MA.
4.
Jain
,
V. K.
,
Kalia
,
S.
,
Sidpara
,
A.
, and
Kulkarni
,
V. N.
,
2012
, “
Fabrication of Micro-Features and Micro-Tools Using Electrochemical Micromachining
,”
Int. J. Adv. Manuf. Technol.
,
61
(9–12), pp.
1175
1183
.
5.
Wang
,
S. H.
, and
Zhu
,
D.
,
2009
, “
Micro Wire Electrode Electrochemical Machining
,”
Acta Aeronaut. Astronaut. Sin.
,
30
, pp.
1788
1794
.
6.
Wang
,
S.
,
Zeng
,
Y.
,
Liu
,
Y.
, and
Zhu
,
D.
,
2012
, “
Micro Wire Electrochemical Machining With an Axial Electrolyte Flow
,”
Int. J. Adv. Manuf. Technol.
,
63
(1–4), pp.
25
32
.
7.
Wang
,
S.
,
Zhu
,
D.
,
Zeng
,
Y.
, and
Liu
,
Y.
,
2011
, “
Micro Wire Electrode Electrochemical Cutting With Low Frequency and Small Amplitude Tool Vibration
,”
Int. J. Adv. Manuf. Technol.
,
53
(5–8), pp.
535
544
.
8.
Wang
,
W.
,
Liu
,
Z. X.
,
Zhang
,
W.
,
Huang
,
Y. H.
, and
Allen
,
D. M.
,
2011
, “
Abrasive Electrochemical Multi-Wire Slicing of Solar Silicon Ingots Into Wafers
,”
CIRP Ann. Manuf. Technol.
,
60
(
1
), pp.
255
258
.
9.
Xu
,
K.
,
Zeng
,
Y.
,
Li
,
P.
, and
Zhu
,
D.
,
2017
, “
Vibration Assisted Wire Electrochemical Micro Machining of Array Micro Tools
,”
Int. J. Precis. Eng.
,
47
, pp.
487
497
.
10.
Qu
,
N. S.
,
Ji
,
H. J.
, and
Zeng
,
Y. B.
,
2014
, “
Wire Electrochemical Machining Using Reciprocated Traveling Wire
,”
Int. J. Adv. Manuf. Technol.
,
72
(5–8), pp.
677
683
.
11.
Wang
,
X.
,
Fang
,
X.
,
Zeng
,
Y.
, and
Qu
,
N.
,
2016
, “
Fabrication of Micro Annular Grooves on a Cylindrical Surface in Aluminum Alloys by Wire Electrochemical Micromachining
,”
Int. J. Electrochem. Sci.
,
11
, pp.
7216
7229
.
12.
He
,
H.
,
Qu
,
N.
,
Zeng
,
Y.
,
Fang
,
X.
, and
Yao
,
Y.
,
2016
, “
Machining Accuracy in Pulsed Wire Electrochemical Machining of γ-TiAl Alloy
,”
Int. J. Adv. Manuf. Technol.
,
86
(
5–8
), pp.
2353
2359
.
13.
Fang
,
X.
,
Li
,
P.
,
Zeng
,
Y.
, and
Zhu
,
D.
,
2016
, “
Research on Multiple Wires Electrochemical Micromachining With Ultra-short Voltage Pulses
,”
Procedia CIRP
,
42
, pp.
423
427
.
14.
Zeng
,
Y.
,
Yu
,
Q.
,
Wang
,
S.
, and
Zhu
,
D.
,
2012
, “
Enhancement of Mass Transport in Micro Wire Electrochemical Machining
,”
CIRP Ann. Manuf. Technol.
,
61
(
1
), pp.
195
198
.
15.
Qu
,
N.
,
Fang
,
X.
,
Li
,
W.
,
Zeng
,
Y.
, and
Zhu
,
D.
,
2013
, “
Wire Electrochemical Machining With Axial Electrolyte Flushing for Titanium Alloy
,”
Chin. J. Aeronaut.
,
26
(
1
), pp.
224
229
.
16.
Mithu
,
M. A. H.
,
Fantoni
,
G.
, and
Ciampi
,
J.
,
2011
, “
A Step Towards the In-Process Monitoring for Electrochemical Microdrilling
,”
Int. J. Adv. Manuf. Technol.
,
57
, pp.
969
982
.
17.
Liu
,
Y.
,
Zhu
,
D.
,
Zeng
,
Y.
,
Huang
,
S.
, and
Yu
,
H.
,
2010
, “
Experimental Investigation on Complex Structures Machining by Electrochemical Micromachining Technology
,”
Chin. J. Aeronaut.
,
23
(5), pp.
578
584
.
18.
Gao
,
X.
,
Hu
,
W.
, and
Gao
,
Y.
,
2013
, “
Preparation of Ultrafine Tungsten Wire Via Electrochemical Method in an Ionic Liquid
,”
Fusion Eng. Des.
,
88
(
1
), pp.
23
27
.
19.
Zhu
,
D.
,
Wang
,
K.
, and
Qu
,
N. S.
,
2007
, “
Micro Wire Electrochemical Cutting by Using In Situ Fabricated Wire Electrode
,”
Ann. CIRP
,
56
(
1
), pp.
241
244
.
20.
Ghoshal
,
B.
, and
Bhattacharyya
,
B.
,
2013
, “
Influence of Vibration on Micro-Tool Fabrication by Electrochemical Machining
,”
Int. J. Mach. Tools Manuf.
,
64
, pp.
49
59
.
You do not currently have access to this content.