Modeling and Simulation of Electrochemical Discharge Machining for Fabrication of Micro-Channel on Glass

Electrochemical discharge machining (ECDM) has shown significant machining potential of micro- and nano-sized product components irrespective of nonconductivity of the material. However, the control of process parameters to obtain optimum process performance is still a challenge due to insufficient knowledge of the physics of the process. Therefore, a finite element study has been performed to explore the physics of the process and analyze the difference between experimental and simulation results with the help of COMSOL Multiphysics (v5.5). The effect of input parameters like applied voltage, electrolyte concentration, tool feed rate and pulse on time on process responses like material removal rate and width overcut has been explored in the present study. A novel approach in numerical simulation has been applied for micro-channel fabrication on glass. The simulation outcomes were compared and validated with experimental results. Simulation results exhibited good agreement with experimental results.