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Electrochemical drilling of deep micro holes with bulk electrodes

: Schubert, A.; Hackert, M.; Meichsner, G.

Fraunhofer-Institut für Keramische Technologien und Sinterwerkstoffe -IKTS-, Dresden:
INSECT 2006, Third International Symposium on Electrochemical Machining Technology : Dresden, October 26-27, 2006
Dresden: Fraunhofer IKTS, 2006
International Symposium on ElectroChemical Machining Technology (INSECT) <3, 2006, Dresden>
Fraunhofer IWU ()
electrochemical drilling; ECM; COMSOL; simulation; multiphysic

The potential of ECM for fast machining of microholes smaller than 100µm in diameter in steel was investigeted. The influence of rotation speed of a micro drill cathode in the electrolyte transport was investigated with a threedimensional COMSOL Multiphysics model. Therefor coupling between fluid dynamics, electric current density and ion transport through diffusion and convection was used. In addition an experimantal setup with a three axes system and high performence motor spindle placed ad the Z-axis was relised. Serveral commercial micro drill electrodes were supplied by an industrial tool manufacturer. The applied electrolyte was a solution of sodium nitrate with a chelating agent. With this setup micro holes with diameters smaller than 200 microns eroded.