Electrochemical Machining of Micro Deep Holes by Using Micro Drill as Cathode

Zhuang      Liu; Angzi      Li; Naiwu      Li; Yongbin      Zeng

Abstract

Helical groove of micro drill is capable to carry away reaction products out of the machining zone and hence to improve machine accuracy and depth in electrochemical machining process. This work presents an investigation of electrochemical machining of micro deep holes by using micro drill as tool electrode. Effects of electrolyte solution type, drill rotation rate and working voltage on machining depth and inlet side gap have been discussed accordingly. Experimental results show that using mixed electrolyte solution assists the process to achieve better machining inlet side gap. Drill rotation rate in range of 5000rpm to 10000rpm does not markedly affect the machining depth and inlet side gap. Machining depth and inlet side gap increases with the working voltage from 6V to 8V.

Keywords: Micro electrochemical machining, micro holes, helical drill, electrolyte, electrochemical reaction, extracting speed, 5wt%NaNO3, EDTA-Na2, machining zone, CW direction, double electric layer, dissolution rate, Faraday’s law, drill rotation rate, Pulse-on time