Modeling and experimental investigation for electrolytic corrosion prevention in high frequency micro EDM using deionized water

The characteristics of the prevention of electrolytic corrosion during micro electrical discharge machining (EDM) using deionized water and high frequency bipolar pulse were investigated. Electrolytic corrosion during micro EDM using deionized water was analyzed using an equivalent electrical circuit based on the electrical double layer theory. Based on the analysis and experimental verification, a narrow positive pulse duration should be provided to the workpiece to prevent corrosion. A negative voltage with zero average applied voltage (V-avg,V- app) is also essential for this purpose. If V-avg,V- app is positive or negative, electrolytic corrosion occurs on the workpiece or tool, respectively. Micro holes and 3D structures without corrosion were successfully fabricated using a high frequency bipolar pulse with a pulse duration of 0.2 mu s and a period of 1 mu s, as well as V-avg,V- app = 0 V.