Electrochemical discharge milling on silica glass using vertically upward tool feeding technique

Machining of silica glass is a challenging task due to its physical properties like brittleness, electrically insulated, etc. Although with the use of electrochemical discharge, it is possible to make holes and channels in silica glass, but the generation of spark discharge and removal of materials is a complex phenomenon in the electrochemical discharge process. Several research works were carried out previously to control the spark discharge as well as machining accuracy using rotational tool, the addition of ultrasonic vibration, including a magnetic field, and the use of different electrolytes, etc. A novel tool feeding technique i.e. using a horizontal tool and vertically upward tool feeding technique was used during milling on glass. The effects of voltage, the tool feed rate (TFR) and the concentration of electrolyte on the material removal rate and machining quality were studied in this work. The machined channel was examined under an optical measuring microscope as well as scanning electron microscope. The machining surface was also observed using a coherence correlation interferometry image to analyze in-depth surface topography of machined channels. Material removal rate and Ra value of the bottom layer were measured. The material removal rate of 6.097 µg/min was noticed at 25 wt% of electrolyte concentration, 40 µm/s of TFR and 45 V of applied voltage. The bottom layer’s surface roughness (Ra) was found as low as 0.222 µm (Ra) at parametric conditions of 40 V, 40 µm/s TFR, and 15 wt% electrolyte concentration by employing the developed novel tool feeding technique.