On energy channelization analysis for ECSM process during fabrication of microchannels in glass

ABSTRACT

In the electrochemical spark machining (ECSM) process, the gas film breakdown from tool edges releases the thermal energy, which ultimately removes the material from the surface of work substrate, and simultaneously changes the tool shape and its dimensions. This change in tool dimensions leads to a variation in energy channelization characteristics. When a tool travels for long durations, it becomes essential to understand energy channelization behavior over different time scales to get insights into machining behavior and their corresponding feature dimensions. Thus, in the current research investigation, the energy channelization behavior for the ECSM process was investigated during the fabrication of serpentine µ-channels in the glass substrate. The underlying process mechanism is also demonstrated by considering the evidence from simulation outcomes, discharge signals, µ-channels’ profiles, and tool electrode shapes recorded over different time scales and locations. The experimental investigations reveal that the energy channelization behavior in the ECSM process changes invariably as the machining progresses. Tool wear is the leading cause of shifting the energy paradigm over the tool edges and subsequently produces non-uniform machined features.

KEYWORDS:

• ECSM
• µ-channels
• tool electrode wear
• energy channelization behavior

Disclosure statement

No potential conflict of interest was reported by the author(s).