ELECTROCHEMICAL MICROMACHINING– REVIEW OF ADVANCED TECHNIQUES

Abstract

A promising non-traditional manufacturing technique for creating high-precision microfeatures in electrically conductive materials without causing heat damage, residual strains, or tool wear is electrochemical micromachining (ECMM). Research efforts to enhance the performance and dependability of ECMM have quickened due to the increasing demand for miniaturized components in aerospace, biomedical, micro-electromechanical systems (MEMS), electronics, and microfluidic applications. Dimensional accuracy, surface integrity, material removal rate (MRR), and process stability are all influenced by a number of parameters, including tool electrode design and hybrid machining techniques. With a focus on cutting-edge tool electrode designs, such as insulated, rotating, tapered, hollow, multi-axis, and vibration-assisted electrodes, this article provides a thorough examination of current advancements in ECMM. The integration of ECMM with complementary technologies like ultrasonic vibration, laser assistance, magnetic field aid, electro-discharge machining (EDM), and jet-based electrolyte systems is also included in the review. While reducing problems like stray corrosion and overcut, these hybrid techniques have shown notable gains in electrolyte regeneration, material removal localization, machining precision, and surface quality.