In the present paper, an attempt has been made to machine micro holes on 500 µm thick borosilicate glass with 370 µm diameter Stainless Steel (SS) tool using Micro-Electro Chemical Discharge Machining (µ-ECDM). The machining parameters considered for the analysis are Voltage (V); Duty Factor (% DF) and Sodium Hydroxide (NaOH) Electrolyte Concentration (wt% C).The output responses are Material Removal Rate (MRR), Tool Wear Rate (TWR) and Radial Over Cut (ROC). Experiments have been conducted using Taguchi L16 Orthogonal Array (OA). Signal to Noise (S/N) ratio technique has been used to optimise the machining parameters for individual output responses. The optimised parameters for maximum MRR are 65 V, 35 wt% C, 65% DF resulted in 890 µg/min of MRR, for minimum TWR and minimum ROC, the optimised machining parameters are 50 V, 20 wt% C, 50% DF resulted in 25 µg/m of TWR and 50 V, 20 wt% C, 50% DF resulted in 10.16 µm of ROC. Further, the Grey Relational Analysis (GRA) technique has been used to optimise parameters and the obtained parameters are 50 V, 20 wt% C and 60% DF which resulted in 365 µg/m of MRR, 25 µg/m of TWR and 33.8 µm of ROC. Abbreviations:ANOVA, ANalysis Of VAariance; DF, Duty Factor; ECM, Electro Chemical Machining; EDM, Electro Discharge Machining; GRA, Grey Relational Analysis; GRC, Grey Relational Coefficient; GRG, Grey Relational Grade; MEMS, Micro-electromechanical system; MRR, Material Removal Rate; OA, Orthogonal Array; ROC, Radial Over Cut; SS, Stainless Steel; S/N, Signal to Noise; TA, Taper Angle; TWR, Tool Wear Rate; µ-ECDM, Micro-electro chemical discharge machining. © 2019, © 2019 Informa UK Limited, trading as Taylor & Francis Group.

Somashekhar S. Hiremath

Department of Mechanical Engineering

IIT Madras is a public technical and research university located in Chennai, Tamil Nadu. Founded in 1959, it is recognised as an Institute of National Importance.

IIT Madras has been ranked as the top engineering institute in India for four years in a row by the National Institutional Ranking Framework of the MHRD

It currently offers undergraduate, postgraduate and research degrees across 16 disciplines in Engineering, Sciences, Humanities and Management. About 596 faculty belonging to science and engineering departments and centres of the Institute are engaged in teaching, research and industrial consultancy.

IIT Madras

Machining of micro-holes on borosilicate glass using micro-electro chemical discharge machining (µ-ECDM) and parametric optimisation

Advances in Materials and Processing Technologies

Micro-Electro Discharge Machining (μ-EDM) is one of the high precision non-conventional machining methods used for the generation of micro sized features like microholes, microchannels, microstructures etc. on any conducting engineering materials with no constraints on hardness and fragileness. In the present work, experiments have been carried out to machine microholes on copper plates using NiP coated hollow copper tool electrodes. The process parameters selected for the study are voltage, capacitance, pulse on- time and coating thickness and studied their effect on Material Removal Rate (MRR), Tool Wear Rate (TWR), Diametral OverCut (DOC), and Taper Angle (TA). Taguchi L 16 orthogonal array experimental plan has been selected to conduct the experiments systematically. Signal-to-Noise ratios and ANalysis Of VAariance (ANOVA) was used to determine the statistically significant factors influencing the process response. ANOVA results indicate that voltage is the most influencing parameter on all output responses. Grey Relational Analysis (GRA) was utilized to determine the optimal combination of μ-EDM parameters used to increase the MRR and simultaneously to minimize the tool wear, the overcut and the taper angle. From the GRA analysis the optimum parameter combination for maximizing MRR and minimizing the TWR, DOC and TA are voltage: 22 V, capacitance: 330 μF, pulse on-time: 120 μs and coating thickness: 10 μm. Response Surface Methodology (RSM) was also carried out to study the effect of interaction between two input parameters on performance characteristics–MRR, TWR etc. The empirical models for each response criteria were obtained using the RSM with the aid of statistical software. © 2017, © 2017 Informa UK Limited, trading as Taylor & Francis Group.

Investigation on machining copper plates with NiP coated tools using tailor-made micro-electro discharge machine

In today's hi-tech engineering world, a lot of engineering materials are being developed for applications in nuclear industry, automotive industry, aerospace industries, etc. These engineering materials are hard, high strength-to-weight ratio, heat resistant and very difficult to machine using conventional machining techniques. So non-conventional machining techniques gain importance in these fields. Electro chemical discharge machining (ECDM) is one such innovative non-conventional hybrid process, which is used to machine the electrically conductive and non-conductive engineering materials. In present research paper, an innovative study has been made to understand the effect of process parameters of ECDM on material removal rate (MRR) and heat affected zone (HAZ) while machining a silicon wafer. The design of experiments is used for experimental layout plan and for the conduction of experiments. The MRR is found to be non-linear behaviour due to many process parameters like voltage, concentration, duty factor, etc. So response surface modelling (RSM) is used for studying the effect of two parameters simultaneously on MRR. The results are validated with obtained experimental results. Copyright © 2014 Inderscience Enterprises Ltd.

International Journal of Manufacturing Technology and Management

Experimental investigation and parametric analysis of electro chemical discharge machining

Advancement of technologies has resulted in the innovation new engineering materials which are very difficult to machine with conventional machining process. To produce intricate features in these materials with conventional machining process will result in poor surface finish and will require thousands of slide movements. So new non-conventional machining process are introduced to machine difficult to machine materials. Electro Discharge Machining (EDM) and Electro Chemical Machining (ECM) are introduced to meet the needs of industry to machine conducting materials. But for non-conducting materials, a hybrid process combining the features of many conventional and non conventional machining process are required. Electro Chemical Discharge Machining (ECDM) is one such innovative non-conventional hybrid process, which can machine the conductive as well as non conductive engineering materials. In present research work, the effect of process parameters of ECDM on Material Removal Rate (MRR) is studied on borosilicate glass. The design of experiments is used for experimental layout plan for the conduction of experiments. As MRR is found to be non linear, Response Surface Modeling (RSM) is used for optimization of process parameters. The obtained results are validated with experimental results. © 2013 The Authors. Published by Elsevier Ltd.

Fulltext

Procedia Engineering

Response surface modelling of micro holes in electrochemical discharge machining process

Micro-abrasive jet machining (µ-AJM) is one of the novel machining processes used for machining brittle materials wherein the mechanism of erosion is brittle fracture and for ductile materials wherein the mechanism of erosion is due to shear fracture on the materials. In the current work, an attempt has been made to find the material removal rate (MRR) and characterisation of micro-holes produced on quartz using silicon carbide abrasives of various grit sizes. The process parameters selected are air pressure, stand of distance (SOD) and abrasive grit size and output responses measured for the experiments are MRR, radial over cut (ROC) and taper angle. Taguchi L 16 orthogonal array has been selected to conduct the experiments. Grey relation analysis (GRA) was utilised to optimise the process parameters to increase the MRR and at the same time reduce the taper angle and ROC. From the GRA, the obtained optimum parameters are 4 bar air pressure, 0.5 mm SOD and Mix 1 (50% of 320+ 50% of 220) for maximum MRR of 3.96 mg/min, minimum ROC of 85 µm and minimum taper angle of 5°. An improvement method has been adopted to overcome the chipping at the bottom edge of the workpiece. © 2019, © 2019 Informa UK Limited, trading as Taylor & Francis Group.

Journal	Data powered by TypesetAdvances in Materials and Processing Technologies
Publisher	Data powered by TypesetTaylor and Francis Ltd.
ISSN	2374068X
Open Access	No