This thesis aims to make advances in the development of an electrochemical machining process, Spark-Assisted Chemical Engraving (SACE). SACE has applications for the machining of features in the sub-millimeter scale in hard and fragile materials. In particular, glass is used in microelectromechanical and microfluidic systems and the processes available to machine it are limited.
SACE is currently an academic process, with limited adoption in industry. This is due to a lack of control over the process, leading to poor repeatability of the machined shapes. The main objective of this research project is the identification of a feedback signal allowing a better control on the process. The measurement of the electric current passing through the electrodes will be studied as a good candidate.
First, the literature in glass micromachining is reviewed. The industry niche that SACE could occupy is identified, mainly in the context of rapid prototyping and small series production. Then, the state of the art of SACE is studied. Current issues are identified and relevant research avenues to improve the process and its adoption in industry are explored.
Secondly, two SACE machines are designed and developed. The first, having a very good positioning accuracy, offers many avenues of research by its flexibility and ease of interface. The control system of this machine is designed and programmed, including a module for AutoCAD allowing the creation of spline tool paths. The second one, simple and low cost, allows execution of tests with low delay. This machine is designed and manufactured using a desktop CNC milling machine.
Finally, a study is completed and submitted to a scientific journal with the purpose of using the current signal in SACE machining. Basic SACE operations are performed with the low-cost machine. Two applications are proposed : non-contact probing, taking advantage of a peak in the current as it approaches the tool, and then monitoring the state of the gas film surrounding the tool, which would affect the stability of the discharges and the uniformity of the material removal.
| Date | 20 Dec 2022 |
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| Original language | French |
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| Awarding Institution | - École de technologie supérieure
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| Supervisor | Lucas Hof (Supervisor) |
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Villeneuve, G. (Author),
Hof (Supervisor),
20 Dec 2022Student thesis: Master's thesis › Master in Engineering: Mechanical Engineering