Micro-channel fabrication on GFRP composite through electrochemical spark machining method and optimization of process parameters

Kumar, Nitesh; Das, Alok Kumar

doi:10.1177/09544054221093302

Cited by 12 publications

(6 citation statements)

References 46 publications

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“…Response Surface Methodology (RSM), a Design of Experiments (DoE) technique, is adopted for optimizing the process parameters as it helps to understand the combined effect of process parameters and their interaction on responses. 29 A five-factor, three-level Central Composite Design (CCD) is defined (with 42 axial points and eight central points), with the upper limit of the factors coded as + 1, the lower limit as 21, and the middle/medium as 0. Table 2 lists the coded and real values of the individual process parameters.…”

Section: Response Surface Methodologymentioning

confidence: 99%

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Influence of process parameters on the catchment efficiency and geometric characteristics in laser metal deposition tracks for building thin-wall parts

Elvis

Kumaraguru

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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This study investigates the influence of process parameters on catchment efficiency and geometric characteristics such as track height, track width, and wetting angle for low energy density inputs in the blown powder Laser Metal Deposition (LMD) process for building thin-walled parts or repair volumes. Initially, a pilot study was conducted to examine the process parameters that affect catchment efficiency and geometric characteristics, from which five different process parameters such as (i) Laser power, (ii) Carrier gas flow rate, (iii) Deposition speed, (iv) Stand-off distance, and (v) Powder feed rate were identified as parameters of significance to the study. The impacts of these process parameters on catchment efficiency and geometric characteristics were investigated experimentally, and the data were analyzed using ANOVA and Response Surface Methodology (RSM). An analytical model was developed to predict the catchment efficiency, which was validated through experimentation. A comparison was made between the analytical, empirical, and experimental models for catchment efficiency, and it was found that the error was less than 8% which shows relatively good agreement between the proposed and experimental measurements. Furthermore, an empirical-statistical method was employed to establish the relationship between the chosen process parameters, catchment efficiency, and geometric characteristics to fabricate a single continuous track. Based on these correlations, a process map was constructed to identify the optimal processing conditions to obtain a single continuous track of IN625 powder on SS304 substrate with a higher catchment efficiency. This study achieved a maximum catchment efficiency of 71% for a low-energy density input.

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Section: Response Surface Methodologymentioning

confidence: 99%

Section: Design Of Experimentsmentioning

confidence: 99%

Influence of process parameters on the catchment efficiency and geometric characteristics in laser metal deposition tracks for building thin-wall parts

Elvis

Kumaraguru

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Machining of micro-channel on glass fibre-reinforced plastic (GFRP) sheet. The minimum micro-channel (WMC), delamination extent (DE) and HAZ are 532.81, 1.09 and 50.52 μm, respectively 106 .…”

Section: Ceramics and Compositesmentioning

confidence: 99%

Process capability of electrochemical discharge machining: A review

Prakash,

Kumar,

Ballav

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Electrochemical discharge machining (ECDM) is a hybrid machining formed by combining the principles of electrochemical machining and electrical discharge machining. The ECDM is unconventional micromachining that can fabricate holes, blind holes, micro-cavities and grooves on brittle insulating materials such as quartz, glass, silicon wafers and different composites that are difficult to machine. These non-conducting materials have sundry applications such as Micro Electric-Mechanical Systems, biomedical and electronics items. The ECDM provides maximum material removal rate and good surface quality with minor tool wear. The study describes how different process parameters affect machining. The assessment mainly focuses on various tool electrode geometries and materials that are used in ECDM. The present article investigates the ramifications of different types of electrolytes and additives mixed in electrolytes used during the ECDM process on the machined zone. This paper comprehensively reviews the effect of change in applied voltage, machining gap and an inter-electrode gap in the ECDM and it also analyses the fabrication of different materials including glass, quartz, ceramics and composites.

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“…This methodology is capable of providing optimal results in a very limited number of experiments. This also aids in minimizing resource waste [28]. The measured values of the responses were entered in the response columns of the design Table 1 (obtained by using Minitab R14 software), and analysis of variance (ANOVA) was carried out for the development of regression equations and to examine its significance level.…”

Section: Design Of Experimentsmentioning

confidence: 99%

Comparison of Maraging Steel Surface Integrity in Hybrid and Conventional Micro-ECDM Processes

2022

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Maraging steel is one of the exotic materials showing the potential for application in the field of the aerospace industry. However, machining these materials with high surface quality and material removal rate is problematic. The micro-electro chemical discharge (MECDM) process is capable of resolving this problem to some extent, however, due to the spark action, it fails to attain a high surface finish. In the current investigation, micro-hole drilling is performed on maraging steel with powder-mixed alumina (1% wt. of Al2O3) using the micro-electro chemical discharge machining (PMECDM) process. The effect of different input process factors, for example, voltage (V), duty cycle (D), the electrolyte concentration (C), are considered for investigating the machining performance, i.e., rate of material removal (MRR) and roughness of surface (SR) of the machined substrate. Further, a comparative analysis is established between micro-ECDM (MECDM) and mixed powder ECDM (PMECDM). The Box–Behnken design is used to conduct all the experiments and analysis of variance (ANOVA) is used to optimize the results. The outcomes reveal that MRR in PMECDM is enhanced by 34%, and the average surface roughness is reduced by 21% over the MECDM process. The maximum MRR was observed to be 2.44 mg/min and the hole machined by the PMECDM results in a cleaner hole wall surface than the MECDM process due to the grinding action by the powder particles. The residual stress measurement indicates that the PMECDM (−128.3 ± 3.85 MPa) has the lowest equivalent stress as compared to the parent material (−341.04 ± 10.24 MPa) and MECDM (−200.7 ± 6.02 MPa) surfaces. The applied voltage is the most significant parameter, followed by the duty factor and electrolyte concentration for enhancing the MRR and surface finish. The addition of powder improves the surface integrity of the machined surface as compared to the surfaces produced by the MECDM processes.

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Micro-channel fabrication on GFRP composite through electrochemical spark machining method and optimization of process parameters

Cited by 12 publications

References 46 publications

Influence of process parameters on the catchment efficiency and geometric characteristics in laser metal deposition tracks for building thin-wall parts

Influence of process parameters on the catchment efficiency and geometric characteristics in laser metal deposition tracks for building thin-wall parts

Process capability of electrochemical discharge machining: A review

Comparison of Maraging Steel Surface Integrity in Hybrid and Conventional Micro-ECDM Processes

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