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Study of Pulse Electrochemical Micromachining using Cryogenically Treated Tungsten Microtools

Balsamy Kamaraj, Abishek
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1352484381

Abstract Details

2012, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Pulse electrochemical micromachining (PECMM) is an unconventional noncontact manufacturing method suitable for the production of micro sized components on a wide range of electrically conductive engineering materials such as metals, semiconductors, and metal matrix composites. Absence of tool wear is a major advantage expected of PECMM. However, tools are often chemically corroded by certain electrolytes used in PECMM. In this thesis a novel approach i.e. cryogenic treatment of in-house made microtools has been studied to reduce/eliminate tool wear in PECMM. An automated PECMM system has been designed and built in-house. A LabVIEW based process monitoring system has been developed for accurate gap control. An analytical model has been developed for the prediction of diameter of the tools produced by PECMM. Using this noncontact machining system ultra-high aspect ratio (400) tungsten microtools have been fabricated for wide range of applications from neural implants to deep micro hole drilling. Excessive wear was noticed during the application of these tools in the micromachining of difficult to machine tungsten carbide. Cryogenic treatment was performed on tungsten microtools to improve the corrosion resistance and obtain increased tool life in PECMM. Process parameters for the PECMM of tungsten carbide metal matric composite were established to ensure higher machining accuracy with lesser short circuits. By using optimum cryogenic cycle parameters, 200% increase in material removal rate, and 45% reduction in tool wear was achieved in the pulse electrochemical micromachining of tungsten carbide metal matrix composite using cryogenically treated microtools.
Sundaram Murali Meenakshi, PhD (Committee Chair)
Hongdao Huang, PhD (Committee Member)
Anil Mital, PhD PE (Committee Member)
94 p.
Mechanics
Electrochemical micromachining; ECM; Cryogenic treatment; Corrosion; Cavitation; Tungsten;

Recommended Citations

Citations

  • Balsamy Kamaraj, A. (2012). Study of Pulse Electrochemical Micromachining using Cryogenically Treated Tungsten Microtools [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1352484381

    APA Style (7th edition)

  • Balsamy Kamaraj, Abishek. Study of Pulse Electrochemical Micromachining using Cryogenically Treated Tungsten Microtools. 2012. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1352484381.

    MLA Style (8th edition)

  • Balsamy Kamaraj, Abishek. "Study of Pulse Electrochemical Micromachining using Cryogenically Treated Tungsten Microtools." Master's thesis, University of Cincinnati, 2012. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1352484381

    Chicago Manual of Style (17th edition)

ucin1352484381
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© 2012, all rights reserved.
This open access ETD is published by University of Cincinnati and OhioLINK.