On performance enhancement of electrochemical discharge trepanning (ECDT) process by sonication of tool electrode

Pawariya, Kapil; Dvivedi, Akshay; Singh, Tarlochan

doi:10.1016/j.precisioneng.2018.08.016

Cited by 31 publications

(10 citation statements)

References 13 publications

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“…The thermocouple and temperature controller (i-therm, AI-7482) were used to maintain the electrolyte temperature. The oscilloscope was utilized to conceive the fundamental background along with the discharge behaviour of the process [37]. Due to its suitable properties, borosilicate glass (properties given in table 1) is emerging as a favourable candidate for microproducts, and was hence used in this study.…”

Section: Experimentationmentioning

confidence: 99%

Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature

Bahar,

Dvivedi,

Kumar

2024

J. Micromech. Microeng.

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Glass vias are emerging as a favourable option for radiofrequency-based micro-electromechanical system packaging. For the micromachining of glass, electrochemical discharge machining (ECDM) could be the most suitable technique if issues pertaining to the process stability are addressed thoroughly. The electrolyte temperature has immense influence on the viscosity and conductivity of the electrolyte, which percolate the stability of the ECDM process. Therefore, this article investigates the effects of the electrolyte temperature and applied voltage on the performance characteristics of ECDM for the micromachining of borosilicate glass. The machining rate (MR) and hole overcut (HOC) of the machined microholes are considered as performance characteristics. A 3D thermal-based finite element model (FEM) was developed for the thermal analysis in the machining zone. In the thermal analysis, the heat flux by thermal discharge was assumed to have Gaussian distribution, and accordingly, temperature profiles in the thermal zone were analyzed by controlling the electrolyte temperature and voltage at various levels. Further processing of temperature profiles in the thermal zone was utilized in the estimation of MR and HOC. Electrostatic-based FEM was utilized to assess the intensity of the electric field in the proximity of the tool electrode to analyze the probable locations of thermal discharge and its impact on the geometrical characteristics of the machined microholes. The simulation outcomes were validated experimentally, and show good agreement. A field emission electron microscope with energy dispersive spectroscopy was used for the characterization of the machined surface to observe the effect of the electrolyte temperature.

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Section: Experimentationmentioning

confidence: 99%

Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature

Bahar,

Dvivedi,

Kumar

2024

J. Micromech. Microeng.

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“…This phenomenon imparts grinding action on the material surface and cleans most of the debris from the surface, hence the MRR increases in the PMECDM process as compared to the MECDM process. On a rise in voltage, the electrolyte concentration, duty factor, and the strength of the spark increases as the energy input to the process increases, therefore, the grinding action rises in addition to the material erosion due to the melting and electro-chemical reaction [18,32]. At a low voltage (30 V) and DF (20%), the MRR is 0.58 mg/min, which is improved by nearly 2.24 times at a high voltage (50 V) and a DF (30%) at 15 wt% of electrolyte concentration.…”

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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“…Anasane [14] and Ghoshal [15] reported that increasing tool vibration amplitude improves the performance characteristics and gap environment of ECM. Pawariya [16] used ultrasonic vibration of tool electrode of ECDM to investigate and enhance deep microholes in difficultto-machine metal materials. Wang [17] reported that tool vibration improves machining the efficiency, surface quality, and gap environment of ECM.…”

Section: Introductionmentioning

confidence: 99%

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Chen

Zhu

2022

Materials

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Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.

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On performance enhancement of electrochemical discharge trepanning (ECDT) process by sonication of tool electrode

Cited by 31 publications

References 13 publications

Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature

Computational modelling and experimental investigation of micro-electrochemical discharge machining by controlling the electrolyte temperature

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

Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

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