An experimental study of process parameters on material removal rate in ECDM process

Bellubbi, Sadashiv; Naik, Ravindra; Sathisha, N.

doi:10.1016/j.matpr.2020.01.510

“…[29]. These observations made are consistent with those investigated by other researchers [4,12]. From ANOVA study, it was noticed that applied voltage (70.13%) is the mostly influencing factor affecting MRR.…”

Section: Influence Of Process Parameters On Response Characteristicssupporting

confidence: 91%

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Bellubbi

¹

,

Nanjundaswamy

²

,

Mallick³

2021

Preprint

Self Cite

2

0

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In this work, machining of microchannel in silica glass was successfully carried out using electro chemical discharge machining (ECDM) process. The experiments were planned according to L27 orthogonal array with applied voltage, stand-off distance (SOD), electrolyte concentration, pulse frequency and pulse-on-time (TON) as control factors. The material removal rate (MRR), overcut (OC) and tool wear rate (TWR) were considered as response characteristics. In this study the effects of control parameters on MRR, OC and TWR have been investigated. The multi-objective optimization of ECDM was carried out through grey relational analysis (GRA) method. Optimal combination of process parameters achieved from GRA was 45V applied voltage, 25wt.% electrolyte concentration, 1.5mm SOD, 400Hz pulse frequency and 45μs TON. ANOVA for GRG study revealed that the applied voltage (70.33%) was most significant factor affecting output responses followed by electrolyte concentration (11.69%), pulse frequency (4.98%) and SOD (4.13%). Furthermore, the regression equations were formulated for the optimum combination to predict the collaboration and higher-order effects of the control parameters. In addition confirmation test was conducted for the optimal setting of process parameters and the comparison of experimental results exhibited a good agreement with predicted values. The microstructural observation of machined surface for the optimum combination was carried out.

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“…Whereas, shorter on-times erodes very little material and generate smaller craters [29]. These observations made are consistent with those investigated by other researchers [4,12]. From ANOVA study, it was noticed that applied voltage (70.13%) is the mostly influencing factor affecting MRR.…”

Section: Effect Of Control Factors On Mrrsupporting

confidence: 90%

“…Recent developments in ECDM process comprises with micro-machining of ceramics, glass, composites, silicon wafer and quartz with enhanced output responses [4]. The performance of ECDM process in terms of width of cut, surface roughness, machining depth, TWR, MRR, heat affected zone, recast layer is mainly dependent on various factors like SOD, voltage, current density, electrolyte concentration, auxiliary electrode material, tool materials, electrolyte and pulse factors of supply.…”

Section: Experimental Workmentioning

confidence: 99%

“…Presently electro chemical discharge machining (ECDM) process is emerging as a cost effective substitute for ultrasonic machining, laser ablation and wet chemical etching to produce micro features in nonconductive materials such as pyrex glass, borosilicate glass, silica glass, silicon wafers, quartz and ceramics [3]. ECDM process is a hybrid process which combines the features of ECM and EDM to produce micro-features like deep holes, narrow channels and small lots in nonconductive materials [3][4]. Chemical and thermal phenomena are the primary mechanisms of this process to erode the material from the work material [5] thereby achieving the advantages of both; electrochemical dissolution as well as electric-discharge erosion from the work material [6].…”

Section: Introductionmentioning

confidence: 99%

“…In the past, several studies have been conducted to investigate the effects of the ECDM process parameters such as pulse frequency, applied voltage, current density, electrolyte concentration, anode to cathode distance, tool feed rate, pulse-on-time, duty cycle, stand-offdistance, different electrolytes, various tool materials etc. The machining of borosilicate glass [4,7], alumina substrate [3], silica glass [1,8], pyrex glass and soda lime glass [9][10][11], fused silica and quartz [3], carbon fiber reinforced polymer (CFRP) [12] on hole geometry, overcut, HAZ, MRR, machining depth, circularity error, surface roughness, tool wear rate etc. have been investigated.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Bellubbi

¹

,

Sathisha

²

,

Mallick³

2021

Silicon

Self Cite

View full text Add to dashboard Cite

In this work, machining of microchannel in silica glass was successfully carried out using electro chemical discharge machining (ECDM) process. The experiments were planned according to L27 orthogonal array with applied voltage, stand-off distance (SOD), electrolyte concentration, pulse frequency and pulse-on-time (TON) as control factors. The material removal rate (MRR), overcut (OC) and tool wear rate (TWR) were considered as response characteristics. In this study the effects of control parameters on MRR, OC and TWR have been investigated. The multi-objective optimization of ECDM was carried out through grey relational analysis (GRA) method. Optimal combination of process parameters achieved from GRA was 45V applied voltage, 25wt.% electrolyte concentration, 1.5mm SOD, 400Hz pulse frequency and 45μs TON. ANOVA for GRG study revealed that the applied voltage (70.33%) was most significant factor affecting output responses followed by electrolyte concentration (11.69%), pulse frequency (4.98%) and SOD (4.13%). Furthermore, the regression equations were formulated for the optimum combination to predict the collaboration and higher-order effects of the control parameters. In addition confirmation test was conducted for the optimal setting of process parameters and the comparison of experimental results exhibited a good agreement with predicted values. The microstructural observation of machined surface for the optimum combination was carried out.

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Experimental Investigation into Electrochemical Discharge Milling of Glass by Bottom Feeding the Tool Electrode

Santra

¹

,

Sarkar

²

,

Doloi

³

et al. 2022

Lecture Notes in Mechanical Engineering

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An experimental study of process parameters on material removal rate in ECDM process

Cited by 12 publications

References 11 publications

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Experimental Investigation into Electrochemical Discharge Milling of Glass by Bottom Feeding the Tool Electrode

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