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Research Papers

Influence of High Duty Ratio and Frequency in WECM Employing In Situ Fabricated Wire Electrode

[+] Author and Article Information
S. Debnath

Production Engineering Department,
Jadavpur University,
Kolkata 700032, India
e-mail: subhrajit.me32@gmail.com

J. Kundu

Production Engineering Department,
Jadavpur University,
Kolkata 700032, India
e-mail: joydeepkundu2012@gmail.com

B. Bhattacharyya

Production Engineering Department,
Jadavpur University,
Kolkata 700032, India
e-mail: bb13@rediffmail.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received March 20, 2017; final manuscript received August 11, 2017; published online September 28, 2017. Assoc. Editor: Don A. Lucca.

J. Micro Nano-Manuf 5(4), 041005 (Sep 28, 2017) (10 pages) Paper No: JMNM-17-1012; doi: 10.1115/1.4037768 History: Received March 20, 2017; Revised August 11, 2017

To adapt with today's rapidly changing world, fabrication of intricate microparts is becoming an urgent need. Manufacturing of these microparts with stringent requirements necessitates the early adoption of different microfabrication techniques. Wire electrochemical machining (WECM) is such a process which removes excess metal by dissolving it electrochemically. This process can easily generate features downscaled to micron ranges and offers several advantages like the requirement of very simple setup, fabrication of accurate complex microfeatures without undergoing any thermal stress, burr formation, and tool wear, which make it superior from other existing micromachining processes. However, this process is new, and little is known about its applicability and feasibility. Hence, the present work is directed towards developing suitable WECM setup to fabricate microfeatures by introducing proper means for enhancing the mass transport phenomenon. The tungsten tool wire for machining has been in situ etched to a diameter of 23.43 μm by a novel approach for retaining its regular cylindrical form and has been implemented during machining. Moreover, the influences of high duty ratio and applied frequency have been investigated on the corresponding width of the fabricated microslits and the experimental results have been represented graphically where the minimum width of the microslit is obtained as 44.85 μm. Furthermore, mathematical modeling has been developed to correlate duty ratio and applied frequency with generated slit width. Additionally, the mathematical modeling has been validated with practical results and complex stepped type microfeatures have been generated to establish process suitability.

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Figures

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Fig. 1

Photographic view of the developed WECM setup

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Fig. 2

Position of the tool wire with the increase in machining duration and equivalent circuit for the double layer

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Fig. 3

Schematic diagram of voltage pulses during machining

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Fig. 4

Optical micrographs of the fabricated tungsten wire: (a) with 60 s of etching time and (b) with 80 s of etching time

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Fig. 5

Change in the wire's diameter with the increase in etching time

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Fig. 6

Schematic diagram of the developed electrolyte flow system

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Fig. 7

Machining with 23.43 μm W wire, 5 V, 40% duty ratio, 1 MHz frequency, and 0.1 M H2SO4

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Fig. 8

Machining with 23.43 μm W wire, 5 V, 30% duty ratio, 1 MHz frequency, and 0.1 M H2SO4 concentration

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Fig. 9

Influence of duty ratio on the width of the microslit

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Fig. 10

Influence of frequency on the width of the microslit

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Fig. 11

Complex stepped microfeature fabricated with 25% duty ratio, 1.25 MHz pulse frequency, 5 V applied voltage, and 0.1 M electrolyte (H2SO4) concentration

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