Experimental Data for Photochemical Machining of Cu-Zn Alloys

Photochemical machining (PCM) is a precise, non-traditional process used for fabricating intricate features in nonferrous alloys. This study aims to optimize PCM parameters for copper-zinc (Cu-Zn) alloys using ferric chloride (FeCl₃) as the etchant. The influence of etchant concentration, temperature, and etching time on surface roughness, material removal rate (MRR), and edge deviation was evaluated using a full factorial design. Surface morphology and alloy composition were analyzed through high-resolution electron imaging and elemental analysis. Results revealed that low-zinc alloys like CuZn10 yielded smoother surfaces and lower MRR due to their reduced chemical reactivity. In contrast, high-zinc alloys like CuZn40 exhibited higher MRR but with increased surface roughness and edge deviation. Statistical validation through ANOVA confirmed the significance of all three process parameters. To address conflicting machining objectives, multi-response optimization was carried out using the overall evaluation criterion (OEC), enabling a balanced trade-off among key responses. The findings emphasize the pivotal role of zinc content in determining etching behaviour and stress the need for alloy-specific parameter tuning. This work offers a structured approach for enhancing precision and efficiency in PCM of Cu-Zn alloys, contributing to better control and predictability in microfabrication processes.