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Electric discharge machining (EDM), a non-traditional process, is widely used for micro-fabrication, such as the thin-cruciform gimbal flexure of a gyroscope. Due to the thermoelectric process of EDM, it induces surface defects and alters the base material’s property, degrading its performance. In the present study, electropolishing (EP) has been performed on a cruciform-shaped ~119.75 µm thin gimbal flexure to remove its surface defects. The gimbal flexure is made by maraging steel 300. It is electropolished with an electrolyte mixture of acetic acid and perchloric acid in a volume ratio of 3:1. The main EP process parameters, namely electrolyte temperature, agitation of magnetic bid, and polishing time, are optimized using the response surface method of statistical design of experiments (DOE). Also, experiments are performed at optimum process parameter conditions to validate the model obtained from DOE. Surface elemental composition changes after EDM, which regain its base composition after EP. The formation of the recast layer on the surface after EDM, which increases hardness, is removed after EP and brings the surface hardness below the base material due to the formation of an oxide layer. Surface morphology after EDM contains several defects, which are entirely removed after EP.

Electropolishing of thin-cruciform gimbal flexure of gyroscope fabricated by electrical discharge machining