Micro-channel cutting on electrically non-conducting materials with electrochemical discharge machining (ECDM) process has drawn an momentous attention in manufacturing field as compared to other existing non-traditional machining processes. In the present research work, an effort has been accomplished to investigate the effects of process parameters namely applied voltage (V), electrolyte concentration (wt%), pulse frequency and duty ratio on different performance features of ECDM viz material removal rate (MRR), overcut (OC) and heat affected zone (HAZ) area during micro-channel cutting on glass. Also, the comparative performance studies during micro-channel cutting have been done by using mixed electrolyte of NaOH & KOH and different tool polarities. Overcut is measured as lower (42.26 µm) when aqueous KOH electrolyte is used and as higher (133.44 µm) for aqueous NaOH electrolyte. HAZ enlarges with enrichment in concentration for both types of electrolyte. It is observed that polarity has a vital role on various machining characteristics. As compared to direct polarity, MRR is found very low (3.2 mg/hr) in reverse polarity of tool. Overcut is found low in KOH electrolyte for both types of tool polarity (i.e. 64.68 µm for direct polarity and 42.27 µm for reverse polarity). The process parameters influence on the surface texture of micro-channels. Micro-crack is noticed for direct polarity of tool.

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