Investigation of electrochemical micromachining on magnesium alloy using hollow tool electrode.

This study investigates the application of Electrochemical Micromachining (ECMM) on magnesium alloy AZ31 using a hollow tool electrode. Magnesium alloys, particularly AZ31, are valued for their lightweight properties and strength-to-weight ratio but pose challenges in precision machining due to their high reactivity and susceptibility to corrosion. Utilizing a hollow tool electrode in ECMM offers potential advantages in precision and control, crucial for micro-scale manufacturing applications. This research focuses on studying the effect of process parameters such as electrolyte composition, voltage, and duty cycle to achieve high-quality micro holes. Experimental results demonstrate the effects of these parameters on machining speed and overcut. Findings indicate that the use of a hollow tool electrode significantly improves the hole geometry and surface integrity of the machined features, making ECMM a viable technique for the micromachining of magnesium alloys. The experimental outcome shows that the maximum MS of 0.439 μm/s was noted with 156 OC. The machining was enhanced by 12 % when compared to traditional submerged machining with a solid tool.