Optimizing Electrochemical Micro Machining Process Parameters for Precision Micro‑Holes machining in Ti‑6Al‑4V Using Silver, Copper, and Tungsten Electrodes

Optimizing Electrochemical Micro Machining Process Parameters for Precision Micro‑Holes machining in Ti‑6Al‑4V Using Silver, Copper, and Tungsten Electrodes | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Optimizing Electrochemical Micro Machining Process Parameters for Precision Micro‑Holes machining in Ti‑6Al‑4V Using Silver, Copper, and Tungsten Electrodes Ganesh Damodar Kale, Sandeep Sharadrao Anasane This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9518112/v1 This work is licensed under a CC BY 4.0 License Status: Under Revision Version 1 posted 14 You are reading this latest preprint version Abstract Electrochemical micromachining (EMM) offers a non-contact, stress-free method for fabricating precise micro-features in hard-to-cut materials like Ti-6Al-4V, thereby overcoming limitations of conventional machining. The work presented in this manuscript examines the influence of major process factors (voltage, duty cycle, frequency) and tool electrode material (silver (Ag), copper (Cu), and tungsten (W)) on micro hole machining accuracy using both experimental and modeling for EMM. Experiments were conducted using various process parameters, including voltage, duty cycle, frequency, and tool material. The optimal process parameters were identified through an optimization technique. The minimum taper angle of 9.96° has been achieved with the help of the obtained optimum process parameters utilizing a silver (Ag) tool electrode. The superior electrical conductivity of the silver (Ag) tool, compared to the Cu and W tool, produced a greater material removal rate of 0.010998 mm³/min. The identified optimal process parameters can be used for machining of microfeatures on the Ti-6Al-4V material. Physical sciences/Energy science and technology Physical sciences/Engineering Physical sciences/Materials science Electrochemical micromachining (EMM) Ti‑6Al‑4V Tool Electrode Microfeatures Full Text Additional Declarations No competing interests reported. Supplementary Files MachiningVideo.mp4 Cite Share Download PDF Status: Under Revision Version 1 posted Editorial decision: Revision requested 21 May, 2026 Reviews received at journal 12 May, 2026 Reviews received at journal 12 May, 2026 Reviewers agreed at journal 10 May, 2026 Reviews received at journal 09 May, 2026 Reviewers agreed at journal 09 May, 2026 Reviewers agreed at journal 09 May, 2026 Reviewers agreed at journal 08 May, 2026 Reviewers agreed at journal 07 May, 2026 Reviewers invited by journal 07 May, 2026 Editor invited by journal 05 May, 2026 Editor assigned by journal 05 May, 2026 Submission checks completed at journal 29 Apr, 2026 First submitted to journal 29 Apr, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9518112","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":641487793,"identity":"f08f26a3-11ef-454e-8243-8c64b39f0c4b","order_by":0,"name":"Ganesh Damodar Kale","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABDElEQVRIiWNgGAWjYFCCNMYHCQwM/AzsDVABCSQShxZmgwcMDJINPAdAPAOitLBJgrVIJKBowQ3k3dMSgIq3SchHPn744OOOP3L8sxsYP/xgsMjDpcXwzLMDBgkMtyUMb6cZG848Y2AscecAs2QPg0QxTi0z0hsSgFrqDGfnsEnzthkkbgBaKg10XmIDHi0HwLbMPMMm/bfNoB6ohfk3Pi3yEmkHG0Ba5CV42KQZ2wwSDCQS2PDaYsDzLJkhweC2hAEP0C+9Z4wNZ9xIbLPsMcBjS3ua+c8fFUBb2g8/fPBzh5w8/4zkwzd+VNThtuUAmIQyGMHKQKQBDvUgWxqQGYy4TB4Fo2AUjIIRDQDg5VcWQDIgVwAAAABJRU5ErkJggg==","orcid":"","institution":"COEP, Tchnological University , Pune","correspondingAuthor":true,"prefix":"","firstName":"Ganesh","middleName":"Damodar","lastName":"Kale","suffix":""},{"id":641487794,"identity":"74090b6c-1922-4cfd-ac68-248be856c0a2","order_by":1,"name":"Sandeep Sharadrao Anasane","email":"","orcid":"","institution":"COEP, Tchnological University , Pune","correspondingAuthor":false,"prefix":"","firstName":"Sandeep","middleName":"Sharadrao","lastName":"Anasane","suffix":""}],"badges":[],"createdAt":"2026-04-24 14:08:15","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9518112/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9518112/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":109760130,"identity":"aa51caee-a5f6-41f3-9678-82611585c3c1","added_by":"auto","created_at":"2026-05-22 07:28:12","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1599005,"visible":true,"origin":"","legend":"","description":"","filename":"EMMforMicroholegenerationV32.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9518112/v1_covered_3340e90f-553e-4704-93ef-5336d2c2a383.pdf"},{"id":109469539,"identity":"71db261b-9b5a-46ce-950a-648c5c41dd7d","added_by":"auto","created_at":"2026-05-18 12:47:14","extension":"mp4","order_by":0,"title":"","display":"","copyAsset":false,"role":"supplement","size":64654052,"visible":true,"origin":"","legend":"","description":"","filename":"MachiningVideo.mp4","url":"https://assets-eu.researchsquare.com/files/rs-9518112/v1/cf3f5134e0ff12f6e779da19.mp4"}],"financialInterests":"No competing interests reported.","formattedTitle":"Optimizing Electrochemical Micro Machining Process Parameters for Precision Micro‑Holes machining in Ti‑6Al‑4V Using Silver, Copper, and Tungsten Electrodes","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"scientific-reports","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"scirep","sideBox":"Learn more about [Scientific Reports](http://www.nature.com/srep/)","snPcode":"","submissionUrl":"","title":"Scientific Reports","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Scientific Reports","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"Electrochemical micromachining (EMM); Ti‑6Al‑4V, Tool Electrode, Microfeatures","lastPublishedDoi":"10.21203/rs.3.rs-9518112/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9518112/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eElectrochemical micromachining (EMM) offers a non-contact, stress-free method for fabricating precise micro-features in hard-to-cut materials like Ti-6Al-4V, thereby overcoming limitations of conventional machining. The work presented in this manuscript examines the influence of major process factors (voltage, duty cycle, frequency) and tool electrode material (silver (Ag), copper (Cu), and tungsten (W)) on micro hole machining accuracy using both experimental and modeling for EMM. Experiments were conducted using various process parameters, including voltage, duty cycle, frequency, and tool material. The optimal process parameters were identified through an optimization technique. The minimum taper angle of 9.96\u0026deg; has been achieved with the help of the obtained optimum process parameters utilizing a silver (Ag) tool electrode. The superior electrical conductivity of the silver (Ag) tool, compared to the Cu and W tool, produced a greater material removal rate of 0.010998 mm\u0026sup3;/min. 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