Edge rounding of micro bores by inverse jet electrochemical machining

In this study a wide scope of technology user, system developers and research institutes have worked together in a cooperation project funded by the European Union through the European Regional Development Fund (ERDF) and from state funds of the Free State of Saxony. Focus of the project was the creation of conditions for a quality-oriented mass production of micro-holes with defined hydraulic flow. After extensive experimental studies for the desired application, the use of shaped electrodes could be detected to be unsuitable. Therefore an inversion of the Jet Electrochemical Machining process has been developed. Starting from the demands of Continental Automotive GmbH a basic validation of the principle of the inverse Jet Electrochemical Machining process was performed by TU Chemnitz and Fraunhofer-IWU by means of multiphysics simulations and experimental investigations [1]. In the next step device and machine system were developed by SITEC Industrietechnologie GmbH and SITEC Automation GmbH. Furthermore the process principle was applied for a patent [2]. The paper starts with the presentation of the principle of the inverse Jet Electrochemical Machining. By help of a variation of selected process parameters the range of the producible micro-shape is shown. Finally, the feasibility of targeted adjustment of the flow of micro bores by the inverse Jet Electrochemical Machining is proved.