Microelectrochemical sparks machining: a modern approach for fabrication of microcomponents from nonconductive materials

Kumar, Nitesh; Mandal, Niladri; Das, Alok Kumar

doi:10.1016/b978-0-12-820049-0.00012-8

Cited by 5 publications

(2 citation statements)

References 118 publications

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“…The discharge phenomenon of micro-ECSM process causes the melting or charring of matrix which is adhere/re-deposited on the edge of the channel. 48 Fiber breakage is also noticed which is may be due to the stick and jump action of the micro tool (Figure 10(a) and (c)). The tip of the uncut fibers are observed as conical in shape (Figure 10(b) and (c)) which is mainly due to the electrochemical dissolution of the glass fiber 39 in the alkaline solution that is, NaOH electrolyte solution.…”

Section: Multi-objective Optimization Of Process Parametersmentioning

confidence: 99%

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

Kumar

Das

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the present study, fabrication of micro-channel on glass fiber reinforced plastic (GFRP) sheet has been performed through micro-electrochemical spark machining process. Box-Behnken design has been followed to conduct experiments and the influence of machining parameters and their ranges that is, applied voltage (50 V–60 V), duty factor (35%–45%), electrolyte concentration (20–30 wt%), and pulse frequency (6–10 kHz) on the micro-channel quality has been investigated. The width of micro-channel (WMC), delamination extent (DE), and heat-affected zone (HAZ) are considered as the responses. Response surface method (RSM) with desirability analysis and multi-objective optimization are utilized to optimize the process. The minimum observed WMC, DE, and HAZ are 532.81, 1.09, and 50.52 μm respectively which are obtained at machining voltage: 50 V, duty factor: 35%, concentration: 20 wt% of NaOH, and pulse frequency: 10 kHz. The fiber breakage and re-deposition/adhesion of broken fiber and matrix materials are observed at the edges of the micro-channel.

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Section: Multi-objective Optimization Of Process Parametersmentioning

confidence: 99%

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

Kumar

Das

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The second process shows better MRR in comparison to the MECDM process. The presence of Al 2 O 3 powder in PMECDM causes grinding action in addition to thermal melting and electro-chemical reactions [18,29,31]. During the discharge process, a shock wave is generated.…”

Section: Effect Of Input Parameters On Mrrmentioning

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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Machining of Maraging Steel Through Al2O3 Abrasive Powder Assisted Electrochemical Discharge Machining

Mandal

Kumar

Das

2022

Lecture Notes in Mechanical Engineering

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Microelectrochemical sparks machining: a modern approach for fabrication of microcomponents from nonconductive materials

Cited by 5 publications

References 118 publications

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

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

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

Machining of Maraging Steel Through Al2O3 Abrasive Powder Assisted Electrochemical Discharge Machining

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