Automated Electrochemical Deburring System for Micro Orifices Using Precision Actuation
Project By: Michael Felix (ME), Brody Matijevic (ME), George Barlow (ME)
Advisor: Professor Sundarram
Background
-
During the drilling of small orifices, tiny metal burrs can form at the edges, especially in stainless steel components.
-
These burrs may block fluid flow, interfere with sealing, or reduce overall part reliability.
-
Aerospace, medical device, and pneumatic component manufacturers often require flawless internal surfaces to ensure performance and safety.
-
Traditional deburring techniques such as manual grinding, thermal deburring, chemical etching, and laser ablation have limitations, including:
-
Inconsistency and operator error (manual grinding)
-
Risk of heat damage (thermal, laser)
-
Difficulty controlling removal in precise areas (chemical)
-
High cost and environmental concerns
-
-
Electrochemical Machining (ECM) is a non-contact method that removes burrs without mechanical stress or heat.
Objectives​
-
Develop an automated system to remove burrs from micro-orifices ranging from 1 to 125 thousandths of an inch.
-
Achieve consistent, sub-micron accuracy in burr removal without damaging surrounding material.
-
Improve upon traditional manual or mechanical methods by offering an automated, scalable, and repeatable solution.
-
Provide a safe, operator-friendly, and cost-effective alternative suitable for industries with precision manufacturing needs.
Methodology​​
-
A conductive needle is insulated along its shaft, exposing only the tip to target burrs inside the orifice.
-
An electrical potential (15V) is applied across the needle and workpiece in a 5% NaCl electrolyte bath, causing controlled material dissolution.
-
Needle depth is calibrated using measurements, not visual feedback. A linear actuator positions the needle based on predetermined travel distances for each orifice size.
-
Testing was conducted on stainless steel parts with machined orifices, first with visible burrs, then examined under magnification post-ECM.
-
Variables such as voltage, electrolyte concentration, and time were controlled. Current configuration: 15V, 10s, 5% NaCl.
​(a) (b)
Material Removal Rate
The main equation we used to determine the material removal rate, MRR, which is in units of g/s:
​​
​
​
where V is the volume of metal removed in units of mm3, t is the time of Electrochemical machining in units of seconds, C is the Electrochemical Constant which has units of mm3/Amp-s, E is the voltage being supplied to the part in units of Volts, A is the surface area of tool which has units of mm2, g is the gap between the tool and the workpiece in mm, and r is the resistivity of the electrolyte which has units of Ohm-mm.
​(a) (b) (c)
Results​
​
​
​
​
​
Fig. 2. (a) Scaling of micro orifice compared to workpiece (b) Workpiece orifice under Keyence microscope before machining (c) Workpiece orifice under Keyence microscope after machining
Discussion​
We initially tested on the workpieces with varying NaCl concentrations of 5%, 7.5%, and 10%. However, due to the high levels of overmachining the micro orifice, we decided to stick with 5% as it yielded the best results under the Keyence microscope. Utilizing the autonomous capability of our apparatus set up, the operator only needs to complete simple tasks such as workpiece placement, adding NaCl solution, and start command with computer. The Arduino IDE provides communication between the linear actuator which regulates the gap between the tool and the workpiece which eliminates sources of error. The 3D printed workpiece holder ensures proper centering between the needle and workpiece while also providing scalability to different geometries in the future.​
Conclusions​​
-
The ECM system successfully removed burrs from micro-orifices with high precision, achieving sub-micron accuracy.
-
5% NaCl electrolyte concentration, 15V voltage, and controlled needle positioning provided consistent material removal and surface quality.
-
Arduino-controlled linear actuation allowed for a repeatable, automated deburring process, improving efficiency.
-
3D-printed workpiece holder offers flexibility for different geometries for further refinements and broader industrial applications.​
​​Fig. 1. (a) Basic Diagram of ECM Procedure using NaCl solution and power supply. (b) SolidWorks Apparatus with linear actuator, tool, and workpiece
Fairfield University School of Engineering & Computing
2025 Dean’s Award for Best Senior Design Project: Automated Electrochemical Deburring System for Micro-Orifices
Throughout both the Fall 2024 and Spring 2025 semesters, our team delivered weekly progress updates, keeping stakeholders informed as the project evolved. Over the course of the year, we developed a comprehensive final report that detailed our experimental approach, key milestones, and overall findings. In April 2025, we presented a research poster at the annual Research Symposium, which concisely captured the project's foundation—from the initial problem and background to our objectives, methodology, results, and discussion. To cap off the Spring 2025 semester, we delivered a 30-slide presentation to an audience of advisors, industry representatives, and faculty from the School of Engineering & Computing. I am proud to share that our team's hard work and dedication were recognized with the Dean's Award for Best Senior Design Project, an honor bestowed upon our team out of more than 30 competing groups.
Group Photo at the annual Research Symposium. Pictured from left to right: Michael Felix (ME), Brody Matijevic (ME), George Barlow (ME).
Final Apparatus of Project which includes the linear actuator, the needle holder, work piece, work piece holder, 3D-Printed Spillway Basin, and wires providing current.
Certificate of the Dean's Award from the School of Engineering & Computing