Experimental study on parameter evaluation of thin metal sheets using photochemical machining

Abstract

This study examines the impact of critical process parameters etchant concentration, etching duration, and temperature on the machining characteristics of thin copper sheets using PCM. Experiments were conducted on copper sheets of varying thicknesses, specifically 0.4 mm and 0.5 mm, to analyze the effects of these parameters on dimensional accuracy. The study systematically varied the concentration of ferric chloride (FeCl₃), a commonly used etchant, to assess its influence on etching depth and precision. The findings suggest that higher FeCl₃ concentrations enhance the etching rate, leading to deeper material removal. However, an excessive concentration may also contribute to surface roughness and undercutting, affecting the overall accuracy. While elevated temperatures generally accelerate chemical reactions and improve etching efficiency, excessive heat can lead to undesired effects, such as uncontrolled lateral etching and reduced precision. Similarly, the etching duration influences the final machining outcome. Overall, the study provides valuable insights into optimizing PCM parameters for precise and controlled micromachining of copper sheets, highlighting the need for a balanced approach to etchant concentration, temperature, and processing time.