Determination of Nanoindentation Behavior of HAZ on Glass Material Machined via ECSM Process through Simulation Approach

Abstract

The current study develops a numerical model to investigate the nanoindentation behavior of heat-affected zones (HAZ) on glass material produced via the electrochemical spark machining (ECSM) method. Initially, microchannels were created using the ECSM method on soda–lime glass. Following that, a nanoindentation test was conducted to quantify the Young’s modulus and hardness of the glass sample. After that, a numerical model based on finite elements was created to characterize the changes in mechanical characteristics of HAZ. According to the findings, increasing the electrolyte concentration from 10 to 30% increases the intensity of electrochemical discharges, and thereby decreases the hardness of the work material by 16.29 to 30.58% compared to unmachined glass. The results obtained from the simulation are in close agreement with the experimental values. The maximum error obtained between simulation and experimental results is only 4.18%.

Recent Trends and Developments in the Electrical Discharge Machining Industry: A Review

“…As part of this we have identified five primary and two nonstandard areas of practical electroapplication (Figure 3). The final outcome is influenced by various factors, including the operational modes and types of the technological process, the processing mechanism, the experimental setup, the choice of dielectric, the electrode tool (ET), the workpiece material, and the condition of both the cathode and anode surfaces [25]. Depending on machining efficiency and surface layer requirements, the process is categorized into four types: roughing [37], semi-finishing [38], finishing [39], and super-finishing [40].…”

“…Wire-electrical discharge machining (WEDM) serves a dual purpose, involving both cutting and contouring processes [25,41,42]. In this method, a wire acts as the ET.…”

“…WEDM is characterized by a complex iterative process that involves an unpredictable cratering mechanism [41]. The processing conditions and the physical, mechanical, and thermomechanical properties of the materials can result in wire breakage and even damage to the material itself [25,42]. Notably, WEDM offers certain advantages, such as effectively providing a constantly renewed tool in the processing zone, and relatively low tool costs [40].…”

“…However, due to the heat-affected zone, WEDM finds its primary application in roughing processes, especially in small-batch production [38]. Wire-electrical discharge machining (WEDM) serves a dual purpose, involving both cutting and contouring processes [25,41,42]. In this method, a wire acts as the ET.…”

“…Die-sinking EDM employs electrical erosion piercing technology [7,8,25,31,40]. The concept of material removal through electrical erosion was pioneered by Boris and Natalia Lazarenko [6,7].…”