Study of Pulse Electrochemical Micromachining using Cryogenically Treated Tungsten Microtools

Pulse electrochemical micromachining (PECMM) is an unconventional noncontact manufacturing method suitable for the production of micro sized components on a wide range of electrically conductive engineering materials such as metals, semiconductors, and metal matrix composites. Absence of tool wear is a major advantage expected of PECMM. However, tools are often chemically corroded by certain electrolytes used in PECMM. In this thesis a novel approach i.e. cryogenic treatment of in-house made microtools has been studied to reduce/eliminate tool wear in PECMM. An automated PECMM system has been designed and built in-house. A LabVIEW based process monitoring system has been developed for accurate gap control. An analytical model has been developed for the prediction of diameter of the tools produced by PECMM. Using this noncontact machining system ultra-high aspect ratio (400) tungsten microtools have been fabricated for wide range of applications from neural implants to deep micro hole drilling. Excessive wear was noticed during the application of these tools in the micromachining of difficult to machine tungsten carbide. Cryogenic treatment was performed on tungsten microtools to improve the corrosion resistance and obtain increased tool life in PECMM. Process parameters for the PECMM of tungsten carbide metal matric composite were established to ensure higher machining accuracy with lesser short circuits. By using optimum cryogenic cycle parameters, 200% increase in material removal rate, and 45% reduction in tool wear was achieved in the pulse electrochemical micromachining of tungsten carbide metal matrix composite using cryogenically treated microtools.

Name thesis:degree_name

MS

Level thesis:degree_level

masters

Discipline thesis:degree_discipline

Engineering and Applied Science: Mechanical Engineering

Grantor dc:publisher

University of Cincinnati

Year dc:date

2012

Author dc:creator

• Balsamy Kamaraj, Abishek

Contributors dc:contributor

• Meenakshi, Sundaram Murali

• Mechanics
• Electrochemical micromachining
• ECM
• Cryogenic treatment
• Corrosion
• Cavitation
• Tungsten

Statement dc:rights

• unrestricted
• This thesis or dissertation is protected by copyright: all rights reserved. It may not be copied or redistributed beyond the terms of applicable copyright laws.

Language dc:language

English

Repository record dc:identifier

http://rave.ohiolink.edu/etdc/view?acc_num=ucin1352484381

OAI identifier oai:identifier

oai:etd.ohiolink.edu:ucin1352484381