Electrochemical micromachining (μECM) is a
non-conventional machining process based on the phenomenon
of electrolysis. μECM became an attractive area of research
due to the fact that this process does not create any
defective layer after machining and that there is a growing
demand for better surface integrity on different micro applications
including microfluidics systems, stress-free drilled
holes in automotive and aerospace manufacturing with complex
shapes, etc. This work presents the design of a next
generation μECM machine for the automotive, aerospace,
medical and metrology sectors. It has three axes of motion
(X, Y, Z) and a spindle allowing the tool-electrode to rotate
during machining. The linear slides for each axis use air
bearings with linear DC brushless motors and 2-nm resolution
encoders for ultra precise motion. The control system is based
on the Power PMAC motion controller from Delta Tau. The
electrolyte tank is located at the rear of the machine and allows
the electrolyte to be changed quickly. This machine features
two process control algorithms: fuzzy logic control and adaptive
feed rate. A self-developed pulse generator has been
mounted and interfaced with the machine and a wire ECM
grinding device has been added. The pulse generator has the
possibility to reverse the pulse polarity for on-line tool
fabrication.
Keywords Micro ECM . PECM . Micromanufacturing .