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Reducing tool wear in micro electrochemical machining by cryogenic treatment

Pulse electrochemical micromachining (PECMM) is an unconventional manufacturing method suitable for the production of micro sized components on a wide range of electrically conductive materials. Absence of cathode wear during electrolysis is a major advantage of electrochemical machining. However, tools are often chemically corroded by certain electrolytes used in PECMM. In this study, cryogenic treatment was performed to improve the corrosion resistance of tungsten tools to achieve increased tool life in PECMM. Using one-way multivariate analysis of variance method, optimum cryogenic cycle parameters for the PECMM were established. Compared to an untreated tool, a reduction of about 10% to 45% in tool wear rate and 0% to 80% in corrosion rates, and 20% to 200% increase in MRR were observed on electrochemical machining with tools that were cryogenically treated.