Control of micro-spark and stray-current effect during EMM process

Improvement of Machining Accuracy

“…accumulation of sludge and gas bubbles in the very small IEG [11]. The increment in gap resistance due to various causes, e.g., gas bubble generation, sludge formation, etc., leads to the occurrence of microsparks, causing larger radial overcut as well as microspark affected zone that results in the poor quality of final products as shown in Fig.…”

Differential search algorithm-based parametric optimization of electrochemical micromachining processes

“…After taking into consideration pulse on/off ratio, machining voltage, electrolyte concentration, voltage pulse frequency and tool vibration frequency as the five major EMM process parameters, Munda et al (2007) studied their influences on micro-spark and stray-current affected zone (MSAZ) (in mm) of the machined surface. The value of MSAZ is quantified as the average difference between the hole radius to the distances between centre of the hole and different points along the curve that indicate the straycurrent and micro-spark affected zone.…”

“…The results of single objective optimization obtained using DSA and GA are exhibited in Table 8. Employing desirability function approach, Munda et al (2007) observed the optimal setting of various process parameters as pulse on/off ratio = 2.1618, machining voltage = 2.8347 V, electrolyte concentration = 10 g/l, voltage frequency = 35 Hz and tool vibration frequency = 100 Hz, and a minimum MSAZ value of 1×10 -4 mm. From Table 8, it is found that the minimum values of MSAZ are 4.1×10 -7 mm and 1.23×10 -4 mm respectively when the same optimization problem is solved using DSA and GA techniques.…”

“…Bhattacharyya et al (2007) carried out experiments to determine the optimal values of different EMM process parameters, such as micro-tool vibration frequency, amplitude and electrolyte concentration for producing micro-holes with higher accuracy and appreciable amount of MRR. Using response surface methodology (RSM), Munda et al (2007) correlated the interactive and higher-order influences of various machining parameters on the combined effect of micro-spark and stray-current machining in an EMM process. Munda and Bhattacharyya (2008) developed a mathematical model for correlating the interactive and higher-order influences of various EMM process parameters, i.e.…”

Analysis and Reduction of Stray-Current Attack in Reciprocated Traveling Wire Electrochemical Machining

“…Passivity electrolyte was introduced for its ability to block the dissolution at the area of low current density by introducing a threshold value of current density [21]. The use of pulsed current [22][23][24], especially ultrashort pulses [3,4], is another progressive technique used to obtain high precision in ECM. Review of the literature has revealed that there is hardly any literature concerning this problem in traveling wire electrochemical machining.…”