Optimization of process parameters in Electro Chemical Discharge Machining of silica glass through Analysis of Means

Abstract

In recent years, the Electro Chemical Discharge Machining (ECDM) process has advanced as a substitute for machining of conductive and non-conductive materials. Optimization of the process parameters plays a crucial role in improving the quality of the processed components. The machining of microchannel in silica glass has been successfully attempted in present work by considering Analysis of Means (ANOM) of ECDM process parameters. The experiments were planned using Taguchi’s L9 orthogonal array with applied voltage, stand-off distance (SOD), electrolyte concentration (EC) and pulse on time (TON) as process parameters. The Material Removal Rate (MRR), Machining Depth (MD) and Overcut (OC) were observed as output characteristics. The ANOM study revealed that the error between experimental and predicted values of MRR, MD and OC are 4.22%, 1.92% and 3.46% respectively. Stand-off distance was found to be the most significant factor followed by pulse on time, applied voltage and electrolyte concentration from ANOVA. Confirmation test was performed by setting the optimum combination of process parameters and the predicted values from regression analysis exhibited a good agreement with experimental results.

Process capability of electrochemical discharge machining: A review

“…In the case of the groove, the surface roughness is directly proportional to the applied voltage and inversely proportional to the frequency of the power supply and the tool electrode feed speed. 117 The ECDM experiment was performed on the lime glass by Harugade et al 56 75 used different tool material electrodes in their experiment for machining the quartz and their result is compared. The tool material electrode is tungsten, tungsten carbide and stainless steel.…”

“…In the case of the groove, the surface roughness is directly proportional to the applied voltage and inversely proportional to the frequency of the power supply and the tool electrode feed speed. 117 The ECDM experiment was performed on the lime glass by Harugade et al 56 by using copper as the tool electrode as well as the auxiliary electrode. The experiment was performed at the voltage of 40–60 V, 10–30% of electrolyte concentration and inter-electrode gap of 20–40 mm, and the MRR was measured in KOH and NaCl electrolyte.…”

A review on micro-drilling by electrochemical discharge machining

“…Grey relational analysis (GRA) was used to optimize ECDM process for MRR, average surface roughness, kerf width, and HAZ [21,86,117]. Analysis of means (ANOM) technique was utilized to get optimum parameters for reducing overcut and maximizing MRR and depth of cut [93]. Rajput et al [118] utilized response surface methodology (RSM) to optimize parameters for obtaining maximum MRR and minimum TWR.…”

“…The gas film in UA-ECDM is thinner than in ECDM, increasing the discharge frequency. Higher discharge frequency in UA-ECDM Brass wire (TW-ECDM) Pyrex glass NaOH V-70 V, EC-200 g L −1 , T ON −500 μs, T OFF −450 μs, WFR-2.4 m min −1 MRR, ASR, K W Modified GRA [93] Tungsten carbide wire (TW-ECDM) Silica glass NaOH V-55 V, EC-17 wt%, IEG-0.5mm, T ON − 60 μs MRR, MD, OC ANOM [118] Stainless steel Soda-lime glass NaOH V-50 V, EC-25 wt%, TFR-4 mm min −1 , IEG-42.35 mm MRR, TWR RSM [119] Copper Tempered glass NaCl V-80 V, EC-30 wt%, DC-80% MRR Taguchi's L9 orthogonal array V-Applied voltage, EC-Electrolyte concentration, T ON -Pulse on time, T OFF -Pulse off time, ASR-Average surface roughness, WFR-Wire feed rate, K W -Kerf width, IEG-Inter electrode gap, MD-Machining depth, OC-Overcut, TFR-Tool feed rate, TWR-Tool wear rate, DC-Duty cycle, GRA-Grey Relational Analysis, ANOM-Analysis of Means, RSM-Response Surface Methodology. leads to higher MRR [42,81] and better depth of penetration [133].…”