Shape control in micro borehole generation by EMM with the assistance of vibration of tool

•An electrical circuit model of electrochemical micromachining is presented for better understanding of the process.•Machining zone is simulated with reversed taper tool and conical tool during EMM of microhole.•Simulated machining zones are verified by experimental results for proper shape control.•Variation of micro nozzle angle with different feed rates of conical tool and times of machining are investigated.•Both reversed taper and forward taper tool can be used for generation of taper less micro holes.

Electrochemical micromachining (EMM) is gaining importance day by day due its advantages that include no tool wear, absence of stress/burr, high MRR, bright surface finish and ability to machine complex shapes regardless of hardness. Overcut and taper formation is the main problem during micro borehole machining. In this paper, an electrical circuit model of EMM is presented for better understanding of the process and experimental MRR is found to be in good agreement with theoretical MRR. In the present set up variation of overcut with voltage, pulsed frequency, vibration amplitude of tool and vibration frequency of tool are investigated. To reduce overcut and taper angle of micro borehole, machining zone is simulated with a reversed taper tool and verified by practical experiments for proper shape control during micro borehole generation. Variation of micro nozzle angle with different feed rates and different times of machining are also investigated for the shape control during micromachining with conical tool. Finally, it has been shown that both reversed taper and forward taper tool can be used for generation of taper less micro features i.e. boreholes.