Machining of circular micro holes by electrochemical micro-machining process

Machining of micro holes with micro electrochemical machining (micro ECM) process has been carried out with an indigenously developed set up. This paper describes relevant problems and solutions for the circular micro holes machining process on 304 stainless steel sheets with 60 μm thickness using high speed steel cylindrical tool of diameter 500 μm and using dilute H2SO4 as electrolyte. The taper angle variation of the machined hole is analyzed and reported for different experimental setting parameters. The minimum value of the taper angle of machined holes is achieved at the parameter setting of 0.4 mol/L H2SO4, 700 kHz, 600 ns and 21 V, for stainless steel sheets and HSS tool.