Manufacturing of micro electrodes using ultra sonic aided electrochemical machining

In this study, a two-steps composite processing technology combining WEDG process, ultra sonic, and electrolysis machining is adapted to cut micro electrodes. Rod electrode of diameter 3.0 mm is cut to be 0.15 mm on wire-EDM machine in first step. A faster metal removal rate can be achieved on anode by ultra sonic aided electrolysis machining. The diameter of the microelectrode could be machined to 10 μm in second step. Results have been revealed fine electrodes could be processed to a desired smaller size using proposed two-steps composite machining technology. With higher L/D ratio, the processed fine electrodes can be used for processing micro holes, deep micro holes, micro slots and manufacturing of micro nozzles.