An electrochemical micro machining (ECMM) set-up has been developed and utilized for experiments. The effects of ECMM parameters on material removal rate and electrode wear rate have been analyzed during micro drilling of hybrid Al/(Al₂O_3p+SiC_p+C_p)-MMC with tungsten electrode of diameter 298 µm. The machined surface texture, and decomposition of metallic compounds deposited on the workpiece as well as on micro tool have been analysed through SEM, EDX and XRD images. It may occur due to the reaction of the anode with electrolyte (NaCl). The formation of a new compound sodalite has been identified. This is due to the reaction between sodium chloride and reinforced particles i.e. Al₂O₃, SiC, C elements presence in hybrid MMC. It has also been identified that the formation of ferropargasite chlorous compound might be due to a chemical dissolution of ferrous material and reaction with sodium chloride. Formation of voids, micro-cracks, craters, debris, pulled out materials and pockmarks have been analyzed during micro machining at high current and pulse-on time parametric setting. From EDX analysis, it has been noticed that the reinforced particles present in hybrid metal matrix composite have been deposited on a micro tool. This is due to the melting and re-solidification of hybrid Al/MMC during machining by micro sparking at high supply voltage and pulse on time.

中文翻译：

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混合MMC电化学显微加工的实验研究。

已经开发出电化学微加工（ECMM）装置并将其用于实验。在直径为298 µm的钨电极混合Al /（Al ₂ O _3p + SiC _p + C _p）-MMC的微钻过程中，分析了ECMM参数对材料去除率和电极磨损率的影响。通过SEM，EDX和XRD图像分析了加工后的表面纹理以及沉积在工件以及微型工具上的金属化合物的分解。它可能是由于阳极与电解质（NaCl）的反应而发生的。已经确定了新的复合方钠石的形成。这是由于氯化钠和增强颗粒（即Al ₂ O）之间的反应_{如图3所示}，在混合MMC中存在SiC，C元素。还已经确定，铁假胃石含氯化合物的形成可能是由于铁类物质的化学溶解和与氯化钠的反应。在高电流和脉冲接通时间参数设置下的微加工过程中，已经分析了空隙，微裂纹，弹坑，碎屑，拉出的材料和斑点的形成。通过EDX分析，已经注意到存在于混合金属基质复合物中的增强颗粒已经沉积在微型工具上。这是由于在高电源电压和脉冲接通时间下通过微火花在加工过程中混合Al / MMC的熔化和重新凝固。