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Journal of Polymer & Composites Original Research Special issue

Investigating the Influence of Process Parameters on Photochemical Machining of Phosphor Bronze Alloy Microchannels

  1. Pradnya Krishna Bhuse Department of Mechanical Engineering, SVERI’s College of Engineering, Pandharpur
  2. Sandeep Sitaram Wangikar Department of Mechanical Engineering, SVERI’s College of Engineering, Pandharpur

Abstract

Microchannels are widely employed in microfluidic devices, biomedical systems, and compact heat exchangers, where their functional efficiency depends strongly on surface finish, dimensional control, and edge quality. Traditional machining techniques often face limitations in producing such features with the required precision, prompting the use of advanced micromachining methods. In the present work, photochemical machining (PCM) has been applied to fabricate serpentine-shaped microchannels in phosphor bronze. The study systematically investigates the effect of three process parameters—etchant concentration, etching duration, and solution temperature—on machining performance. Ferric chloride was employed as the etchant, and a full factorial design of experiments was used to develop the experimental framework. The fabricated samples were examined through optical microscopy to evaluate edge sharpness and surface smoothness. Statistical validation was carried out using analysis of variance (ANOVA) to quantify the influence of process variables. Results confirm that etchant concentration and temperature are the most significant contributors to etch rate and machining quality, while etching duration plays a secondary role. The study revealed that surface roughness (Ra) increased with higher etchant concentration, temperature, and etching time, whereas edge sharpness (ES) improved with concentration and temperature but declined with prolonged etching. Optimal conditions for the minimum Ra were achieved at a concentration of 250 g/L, 35 °C, and 5 minutes, while the lowest ES occurred at the same concentration and temperature, with 21 minutes of etching. Overall, the study demonstrates that careful optimization of PCM parameters can produce precise and reliable microchannels, making the process highly relevant for engineering and biomedical applications.

Keywords

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