Experimental Investigation to Improve Metal Removal Rate (MRR) and Surface Roughness in Electrochemical Machining

Shather, Saad Kariem; Ahmed, Baqer Ayad

doi:10.30684/etj.30.11.9

ETJ

2012

DOI: 10.30684/etj.30.11.9

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Experimental Investigation to Improve Metal Removal Rate (MRR) and Surface Roughness in Electrochemical Machining

Saad Kariem Shather¹,

Baqer Ayad Ahmed²

Abstract: Electrochemical machining (ECM) is a non-traditional machining process which is the controlled removal of metal by anodic dissolution in an electrolytic cell in which the workpiece is the anode and the tool is cathode. In ECM, metal removal rate (MRR) takes place due to atomic dissolution of work material. Electrochemical dissolution is governed by Faraday's laws.I n this study the ECM is used to remove metal from the internal hole of the workpiece from aluminum alloy using NaCl solution.

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2024

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Effect of the hollow electrode on the material removal rate of titanium alloy (grade 1) in the electrochemical machining (ECM) process

Maktuf,

Shwaish,

Aghdeab

2024

BIO Web Conf.

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This study examined the material removal rate (MRR) affected by the variables of the electrochemical process including electrode type, voltage, electrolyte type, electrolyte concentration, and gap. Titanium alloy was employed as the workpiece, while copper was utilized as the cylindrical electrode. The input parameters were established according to Taguchi’s methodology. An analysis of variance (ANOVA) using a linear regression model was dependent on making sense of the experiment’s findings. the solid electrode achieved the maximum material removal rate (MRR) value (0.0857) g/min, while the hollow electrode with (1500 l/hour) flow rate achieved the minimum material removal rate (MRR) value (0.00002) g/min. the material removal rate (MRR) was directly proportional to the voltage. Maximum material removal rate (MRR) occurred at a concentration of (75 g/l) for the (NH4C) electrolyte, while minimum material removal rate (MRR) occurred at a concentration of (50 g/l) for the (NH4Cl) electrolyte. It has been observed that the contributing factors in controlling material removal rate (MRR) were as follows; (66.67%) for the voltage, (5.89%) for the electrode, (5.72%) for the electrolyte concentration, (3.24%) for the type of electrolyte, and (3.07%) for the gap.

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Effect of the hollow electrode on the material removal rate of titanium alloy (grade 1) in the electrochemical machining (ECM) process

Maktuf,

Shwaish,

Aghdeab

2024

BIO Web Conf.

View full text Add to dashboard Cite

show abstract

Influence of Electrolyte Concentration on Metal Removal Rate and Surface Finish Quality in Electrochemical Machining Masking

Elawadi,

Alshoaibi,

Hadidi

2024

Yanbu Journal of Engineering and Science

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Electrochemical machining (ECM) is a specialized and precise manufacturing technique involving selective metal removal to achieve the desired shape or form. This article’s primary focus is examining the technical facets associated with the procedure. The elements mentioned encompass the system’s design and optimization, the electrolyte solution’s careful selection, and the precise control of the etching parameters. When considering the overall framework, it is essential to consider important factors such as the concentration of electrolytes, the operational voltage, and the value of the current flowing through the system. The main objective of this study is to evaluate the influence of different concentrations of sodium chloride electrolyte on the metal removal rate (MRR). This will be achieved by utilizing a direct current power supply. The present investigation used aluminum, steel, and stainless steel materials as the substrate for experimentation. These materials were selected to have identical dimensions for the anode and cathode. The main objective of this study is to evaluate the influence of varying concentrations (0.5, 1, 1.5, and 2 mole/liter) of sodium chloride electrolyte on the material removal rate and surface roughness. The findings have been disclosed, revealing the utmost removal rate for aluminum, steel, and stainless-steel materials across all levels of electrolyte concentration. The experimental information is currently presented, related to the rates of metal removal at various electrolyte concentrations of 2 moles per liter. The rates of mass loss observed in aluminum are comparatively higher when compared to those surveyed in steel and stainless steel. The roughness of a machined surface is inversely proportional to the concentration of the electrolyte.

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Experimental Investigation to Improve Metal Removal Rate (MRR) and Surface Roughness in Electrochemical Machining

Cited by 2 publications

References 3 publications

Effect of the hollow electrode on the material removal rate of titanium alloy (grade 1) in the electrochemical machining (ECM) process

Effect of the hollow electrode on the material removal rate of titanium alloy (grade 1) in the electrochemical machining (ECM) process

Influence of Electrolyte Concentration on Metal Removal Rate and Surface Finish Quality in Electrochemical Machining Masking

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