Research on the process of microelement electrochemical machining (μ-ECM)

Project coordinator
Institute of Advanced Manufacturing Technology in Krakow, Poland.

Partners
Institute of Mechanics and Design, Warsaw University of Technology, Poland; The Otto von Guericke University of Magdeburg, Germany; ECMTEC GmbH, Germany; Zimmer & Krein GmbH, Germany; Krakow University of Technology, Poland; Polspecial, Poland; Marcosta Poland.

Aim of project
Theoretical and experimental study in order to understand micro-shaping processes and phenomena during μPECM so as to properly model and control advanced machining. Two approaches taken into account:
– μ-PECM in which nanosecond pulses will be applied and for high dissolution process localization specifi c properties of double layer are taken into account,
– μ-PECM in which time of voltage pulse will be in the range of: ti = 0.5–10 μs and current density up to 100 A/cm2; in this case the high dissolution process localization is obtained by high current density;

To work out a mathematical model and programmes for computer simulation of μ-ECM drilling and of μ-ECM-CNC electrochemical machining process of small details (D << 0.5–1.0 mm) or in case of approaches A and B;

To work out a test stand for experimental tests of electrochemical sinking and ECM-CNC (milling) machining processes of small details (D << 0.5–1.0 mm) in case of approaches A and B;

To work out a concept of a machine–tool for machining details of dimensions of D << 0.5–1.0 mm for approaches A and B;

To developing new micro-machining methods of tools and tooling for fabrication MEMS and other microdetails;

To implement new micro-manufacturing methods to fabricate micro-mechanisms (for instance for MEMS).

expected results
Software for simulation processes and selection of parameters of pulse electrochemical(μ-PECM). The developed new methods of micro-fabrication have great potential for future applications in micro moulds/die and MEMS.