The Effects of Tool Electrode Size on Characteristics of Micro Electrochemical Machining

In micro electrochemical machining using ultra short pulses, the machining rate is significantly influenced by the tool electrode area. As the tool area increases, the electrical double layer capacitance increases and the electrolyte resistance decreases. As a result, the rising time of the double layer potential increases and it is more difficult to obtain effective machining potential within the ultra short pulse duration. A simple insulation method using enamel coating on the side wall of the tool electrode is introduced. The insulated tool electrode was not sensitive to the machining depth and was effective for machining high aspect ratio structures.