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Electrochemical Microslot Machining by Ultrasonic-Vibration-Aided Electrolyte on Nitinol Wire

In this research, the main purpose was to study the applicability of a machining method on microscale medical-equipment manufacturing. The characteristics of wire electrochemical micromachining (WECMM) against NiTi 50-50 wire was investigated. The study utilized a tungsten wire 0.03 mm in diameter as an electrode to cut a fine slot into the nickel–titanium wire. In order to reach a high-precision WECMM finish, an ultrashort pulse power generator was used as a power source to minimize the stray current effect, thus improving the machining accuracy. During the process, various machining parameters were tested for their effects on machining characteristics. In addition, ultrasonic-vibration-aided WECMM was investigated to determine whether it benefited the machining characteristics. The experiment’s results showed that under such an experiment setting, microslots can be successfully manufactured. Furthermore, with the advance adjustment of experimental parameters, the machining accuracy was improved. Finally, a fine slot was manufactured under the optimum experiment parameters and aided by ultrasonic vibration.