Effect of machining parameters on edge-chipping during drilling of glass using grinding-aided electrochemical discharge machining (G-ECDM)

Ladeesh, V. G.; Manu, R.

doi:10.1007/s40436-017-0194-5

Cited by 15 publications

(9 citation statements)

References 17 publications

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“…The trepanning operation was used to remove material from the periphery for making large diameter hole. Another study conducted by Ladeesh and Manu 20 developed a 3D finite element model to predict the edge chipping initiation region and the thickness of the chipped portion during G-ECDD of glass. The technique of using abrasive tool to improve MRR and drilled hole quality was investigated for electrochemical machining by several researchers.…”

Section: Introductionmentioning

confidence: 99%

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

Ladeesh

Manu

2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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The electrically non-conductive materials like glass, ceramics, quartz, etc. are of great interest for many applications in modern industries. Machining them with high quality and at a faster rate is a challenging task. In this study, a novel technique called grinding aided electrochemical discharge drilling (G-ECDD) is demonstrated which uses a hollow diamond core drill as the tool for performing electrochemical discharge machining of borosilicate glass. The new hybrid technique enhances the material removal rate and machining accuracy to several folds by combining the thermal melting action of discharges and grinding action of the abrasive tool. This paper presents the experimental investigation on the material removal rate during G-ECDD of glass while using different electrolytes. An attempt has been made to explore the influence of electrolyte temperature on G-ECDD performance by maintaining the electrolyte at different temperatures. Experiments were conducted using three different electrolytes which include NaOH, KOH, and the mixture of both. The results obtained from this study revealed that an increase in temperature will favor chemical etching as well as electrochemical reaction rate. Also, it was observed that heating the electrolyte leads to an increase in the bubble density and enhances the ion mobility. This causes the formation of gas film at a faster rate and thereby improving the discharge activity. Thus, machining will be done at a faster rate. Better results are obtained while using a mixture of NaOH and KOH. From the microscopic images of the machined surface, it was observed that material removal mechanism in G-ECDD is a combination of grinding action, electrochemical discharges, and chemical etching. Response surface methodology was adopted for studying the influence of process parameters on the performance of G-ECDD. The new technique of grinding aided electrochemical discharge drilling proved its potential to machine borosilicate glass and simultaneously offers good material removal rate, repeatability, and accuracy.

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Section: Introductionmentioning

confidence: 99%

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

Ladeesh

Manu

2018

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…By using this absorbed heat, the workpiece material starts to melt. Ladheesh and Mano 15 studied the theoretical analysis of ECDM drilling assisted with grinding operation. In which, the factors namely, voltage and density of the material effectively affect the MRR rate of both operations.…”

Section: Materials and Methodologymentioning

confidence: 99%

“…In ECDM, the delay in the ignition is minimized by maintaining the applied voltage is maximum of critical voltage. 15 Due to the application of spark, the generated heat (E) in joules is given as follows, Besides, during operation, hydrogen is formed at the cathode due to the passing of electric current. This tends to the formation of a large number of bubbles.…”

Section: Mrr ¼ ρFvmentioning

confidence: 99%

“…The author finalized that the aspect ratio (L/D) of Rotary mode based‐Electrochemical Discharge Drilling (ECDD) was 23.07 times superior to the conventional ECDD. In the glass, the formation of edge chipping on the machined hole entrance was minimized by Ladeesh and Manu 15 using the ECDM approach. In which, the initiation of edge‐chipping has occurred at the region with maximum normal stress.…”

Section: Introductionmentioning

confidence: 99%

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Prediction on enhanced electrochemical discharge machining behaviors of zirconia‐silicon nitride using hybridDNNbased spotted hyena optimization

Manoharan

Sekar²

2022

Intl J of Energy Research

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Summary In this work, zirconia composite is machined by the unconventional Electrochemical Discharge Machining (ECDM). Normally, the machining of zirconia is an inconvenient process due to its increased hardness and maximum machining time. The ECDM of zirconia‐silicon nitride is done by varying the input parameters such as electrolytic concentration, voltage, and duty cycle. The measured output machined parameters are material removal rate (MRR), Overcut (OC), and Tool wear rate (TWR). In Response Surface Methodology (RSM), the Box Behnken method is used to plan the experimental design of this work. The parameter optimization is conducted using RSM. Besides, the experimented machining performances are validated using hybrid Deep Neural Network‐based Spotted Hyena optimization (DNN‐SHO) done in MATLAB platform version 2020 a. From the findings, the voltage and electrolytic concentration are identified as signified parameters for improving the ECDM performances from the RSM analysis. The obtained favorable machining performances are 0.371 mg/min of MRR, 162.2 μm of OC, and 0.26 mg/min of TWR. The predicted results from the proposed DNN‐SHO for the MRR are 0.402 mg/min, OC is 152.98 μm, and TWR is 0.21 mg/min. The proposed DNN‐SHO outcomes are in perfect agreement with the experimented values and are more superior to the RSM, DNN, and DNN‐PSO based prediction approaches.

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“…The hollow diamond core drills shown good consistency in the performance. They also recommended the use of a full rigid support to the workpiece and the use of low-energy power supply to reduce the edge chipping thickness [29]. Another work conducted by Ladeesh and Manu [30] used a solid abrasive engraving tool for developing fluidic channels on borosilicate glass.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

Ladeesh

Manu

2018

J Braz. Soc. Mech. Sci. Eng.

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Machining of advanced glass ceramics is of great importance and is a challenging task for the modern industries. In this study, a new hybrid technique of grinding-aided electrochemical discharge drilling (G-ECDD) is attempted which combines the grinding action of a rotating abrasive tool and thermal melting action of electrochemical discharges to perform drilling of borosilicate glass. G-ECDD is performed using a normal electrochemical discharge machine setup with a provision for using a rotating diamond-coated drill tool. The tool used is a hollow diamond core drill rather than the traditional solid abrasive tool. A spring-fed tool system was designed and developed to provide the tool-feed movement which will also help to maintain a balance between grinding action of diamond grits and thermal melting action of discharges. Preliminary experiments are conducted to identify the optimum spring force of the spring-fed system and tool rotational speed which can facilitate a balanced ECDM and grinding action for material removal. The effect of machining parameters like voltage, duty ratio, pulse cycle time and electrolyte concentration on material removal rate (MRR) and hole radial overcut (ROC) is investigated using response surface methodology (RSM). Duty ratio and voltage are found to be the most significant factors contributing MRR. Voltage and pulse cycle time are identified as the main factors controlling radial overcut of the drilled holes. Second-order regression models for MRR and ROC are developed using the data collected from the experiments using RSM. Grey relational analysis was used to optimize this multi-objective problem. A voltage of 90 V, duty ratio of 0.7, cycle time of 0.002 s and an electrolyte concentration of 3.5 M are found to be the best combination for optimizing the responses. Deterioration of bonding material and dislodging of diamond grits are found to be the major modes of tool wear during G-ECDD. The use of high-frequency pulsed DC increased the tool wear rate due to the less time available for heat dissipation between discharge cycles. Moreover, the wear at the end face of the tool will be accelerated due to the concentration of current density at edges during high-frequency operation. From the microscopic images of the machined surface, the material removal mechanisms involved in G-ECDD are found to be a combination of thermal melting by discharges, grinding action of diamond grits and high-temperature chemical etching effect of the electrolyte.

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Effect of machining parameters on edge-chipping during drilling of glass using grinding-aided electrochemical discharge machining (G-ECDM)

Cited by 15 publications

References 17 publications

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

Prediction on enhanced electrochemical discharge machining behaviors of zirconia‐silicon nitride using hybridDNNbased spotted hyena optimization

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

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