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An investigation of energy utilization behavior on borosilicate glass through heating and stirring of the electrolyte in electro-chemical discharge machining

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Abstract

Owing to its non-conducting nature, Through Glass Vias (TGV) is a new paradigm to reduce the losses in high-frequency transmission systems. However, due to brittleness and non-conducting nature, micro-machining of glass is challenging. In the backdrop of limitations of the existing processes, Electro-chemical Discharge Machining (ECDM) is an evolutionary micro-machining process for brittle and non-conducting materials, like glass. ECDM is a hybrid of electro-chemical and electro-discharge processes. During machining in ECDM, poor flushing coupled with poor replenishment of electrolyte deteriorates the Energy Utilization Behavior (EUB), particularly in hydrodynamic regime. Therefore, the present article deals with a novel approach (using a magnetic stirrer) of Temperature-assisted ECDM (termed as T-ECDM) to improve the energy utilization behavior in the micro-machining of borosilicate glass. The T-ECDM approach has the capability to control the temperature and stirring rate of the electrolyte. The Machining Rate (MR) as well as Aspect Ratio (AR) of micro-hole are considered as the desirable performance indicator, while Tool Wear Ratio (TWR) and Heat-Affected Zone (HAZ) are considered undesirable performance indicator of EUB. The experimental investigation indicated the improvement in Overall Energy Utilization Index (OEUI) by T-ECDM as compared to ECDM. The morphological, composition analysis, and surface profiles of micro-hole witnessed the improved flushing and etching in T-ECDM than ECDM that resulted in better surface finish of the micro-hole. It implies better energy utilization behavior in terms of surface characteristics also.

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Data availability

The datasets generated during the current study are available from the corresponding author on reasonable request.

Abbreviations

ECDM:

Electro-chemical discharge machining

T-ECDM:

Temperature-assisted ECDM

TGV:

Through glass vias

TSV:

Through silicon vias

MEMS:

Micro-electro-mechanical system

EUB:

Energy utilization behavior

MR:

Machining rate

AR:

Aspect ratio

TWR:

Tool wear rate

HAZ:

Heat-affected zone

OEUI:

Overall energy utilization Index

LBM:

Laser beam machining

USM:

Ultra sonic machining

AJM:

Abrasive jet machining

DC:

Direct current

ECC:

Electro-chemical cell

FESEM:

Field emission scanning electron microscope

EDS:

Energy-dispersive spectroscopy

ρ b :

Gas bubble density

ρ l :

Electrolyte density

\(\gamma\) :

Contact angle (mean) between electrode and bubble.

\(R\) :

Bubble radius

\({V}_{b}\) :

Bubble volume

σ:

Surface tension at the interface of bubble with electrolyte

\(\varnothing\) :

Receding angle

\(\theta\) :

Advancing angle

Rs :

Spark radius

\({T}_{e}\) :

Electrolyte temperature

\({P}_{e}\) :

Partition energy

k:

Electrical conductivity

K:

Thermal conductivity

\(\alpha\) :

Temperature coefficient

\(\rho\) :

Density of the workpiece

\({C}_{p}\) :

Specific heat (at constant pressure)

EG:

Energy generated

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  1. Advanced Manufacturing Processes Laboratory, Department of Mechanical and Industrial Engineering, Indian Institute of Technology (IIT) Roorkee, Roorkee, 247667, India

    Dil Bahar, Akshay Dvivedi & Pradeep Kumar

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  1. Dil Bahar
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All authors contributed to the study conception and design. Literature survey, data analysis, and writing of the draft were performed by DB. Supervision and editing of the manuscript were carried out by AD and PK. All authors read and approved the manuscript.

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Correspondence to Pradeep Kumar.

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Appendix 1

Appendix 1

The statistical values for desirable and undesirable characteristics are tabulated in Tables 2 and 3, respectively

Table 2 Statistics of models for desirable characteristics
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Table 3 Statistics of models for undesirable characteristics
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Bahar, D., Dvivedi, A. & Kumar, P. An investigation of energy utilization behavior on borosilicate glass through heating and stirring of the electrolyte in electro-chemical discharge machining. J Appl Electrochem 54, 341–360 (2024). https://doi.org/10.1007/s10800-023-01956-2

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