Effect of Electrolyte Level during Electro Chemical Discharge Machining of Glass

Electro chemical discharge machining (ECDM) is a hybrid machining process. This process has potential application for micro fabrication in nonconductive work materials such as glass. Micro fabricated holes and channels on glass are widely used in micro electro mechanical systems and bio medical devices. ECDM process takes place in an electrolytic cell consisting electrolyte upto certain level above workpiece. This electrolyte level affects the machining efficiency and quality of fabricated micro hole or channel. In this article, the electrolyte level was varied from 0.1 to 4 mm to investigate the effect on process responses of ECDM during fabrication of micro hole in glass. The process responses were material removal rate, depth of cut, heat affected zone and overcut. The effect of electrolyte level was characterized by spark discharge on voltage time wave form and microscopic images. The results revealed that an optimal value of electrolyte level is required for precise machining. (C) 2018 The Electrochemical Society.