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<p>Electrochemical discharge milling (ECD&#xa0;milling) is a widely recognized process for machining electrically non-conductive materials, offering significant advantages over conventional methods. Unlike traditional milling, which relies on mechanical cutting or abrasion, ECD&#xa0;milling removes material through spark discharge and chemical etching. This results in minimal tool wear, reducing both heat generation and environmental impact. Conventional methods, on the other hand, experience higher tool wear and produce more heat and waste. ECD&#xa0;milling is especially effective for precision machining in industries like aerospace, where minimal wear and fine surface finishes are critical. In this study, a new tool-feeding technique was employed to improve the removal of machined products by self-circulating electrolytes in the machining area. Electrochemical discharge milling was performed on polycarbonate, a thermoplastic polymer, using aqueous KOH as the electrolyte. The process parameters were set to 40&#xa0;V, a tool feed rate of 50&#xa0;µm/sec, and an electrolyte concentration of 20&#xa0;wt.%. The results showed a channel width of 594.111&#xa0;µm and a surface roughness (Ra) value of 0.410&#xa0;µm. The enhanced electrical conductivity and chemical etching effects of the KOH solution contributed to smaller spark-affected zones (SAZ), improving machining quality.</p>

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Fabrication of Microchannels on Polycarbonate Using Electrochemical Discharge Milling

  • 期刊论文

  • 发表日期：

    2025年4月29日

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  • S. Santra,
  • B. R. Sarkar,
  • B. Doloi,
  • B. Bhattacharyya

摘要

Electrochemical discharge milling (ECD milling) is a widely recognized process for machining electrically non-conductive materials, offering significant advantages over conventional methods. Unlike traditional milling, which relies on mechanical cutting or abrasion, ECD milling removes material through spark discharge and chemical etching. This results in minimal tool wear, reducing both heat generation and environmental impact. Conventional methods, on the other hand, experience higher tool wear and produce more heat and waste. ECD milling is especially effective for precision machining in industries like aerospace, where minimal wear and fine surface finishes are critical. In this study, a new tool-feeding technique was employed to improve the removal of machined products by self-circulating electrolytes in the machining area. Electrochemical discharge milling was performed on polycarbonate, a thermoplastic polymer, using aqueous KOH as the electrolyte. The process parameters were set to 40 V, a tool feed rate of 50 µm/sec, and an electrolyte concentration of 20 wt.%. The results showed a channel width of 594.111 µm and a surface roughness (Ra) value of 0.410 µm. The enhanced electrical conductivity and chemical etching effects of the KOH solution contributed to smaller spark-affected zones (SAZ), improving machining quality.