Experimental investigation and multiphysics simulation on the influence of micro tools with various end profiles on diametrical overcut of holes machined using electrochemical micromachining for a predetermined optimum combination of process parameters

Electrochemical micromachining (EMM) process is generally applied to shaping of electrically conductive materials which has been gaining popularity in the production of biomedical, MEMS, aerospace and nuclear components. The dimensional accuracy is affected by various process parameters of EMM and by the end profile of the cathode (tool) used to machine the feature. In this study, it is proposed to investigate the EMM process to know the influence of various process parameters on the diametrical overcut of the machined hole and the optimum combination of process parameters to produce holes with minimum diametrical over cut. A bare electrode with flat end is used for this purpose. Later, insulated electrode with flat end and bare electrodes with various end profiles are used to drill holes at the optimum combination of process parameters on Titanium grade II sheet to identify the most suitable micro tool to produce holes with minimum diametrical overcut and minimum stray machined zone. The EMM process of drilling holes using insulated electrode with flat end and bare electrodes with various end profiles are simulated at the optimum combination of process parameters using COMSOL Multiphysics V4.2a software. Results justified the use of multiphysics simulation to understand the process before conducting experiments so that costly trial and error experiments can be reduced to a minimum.