Electrochemical Micromachining: A Review on Principles, Processes, and Applications

Electrochemical micromachining (ECMM) is an advanced non-traditional machining process that utilizes electrochemical principles to shape and contour various conductive materials. This review paper aims to provide an overview of ECMM including its principles, processes, and applications. Electrochemical micromachining (ECMM) has attracted a lot of research interest due to its unique ability to produce flawless surfaces. This is because there is a growing need for perfect surface quality in micro-applications like microfluidic systems and the production of intricate precision holes in complex shapes for the automotive and aerospace manufacturing industries. The paper begins by elucidating the fundamental principles underlying ECMM emphasizing the interaction between the workpiece and the electrolyte in the presence of an electric field. The electrochemical reactions involved in ECMM such as anodic dissolution and metal deposition are explained in detail to elucidate the material removal mechanisms. This review paper aims to provide a comprehensive understanding of ECMM, its underlying principles various processes, and diverse applications. It serves as a valuable resource for researchers, engineers, and practitioners interested in exploring the potential of ECMM for precision machining in modern industries.