Effect of coated and geometrically modified tools on performance of electrochemical micromachining

Soundarrajan, M.; Thanigaivelan, R.

doi:10.1080/10426914.2020.1740252

Cited by 19 publications

(6 citation statements)

References 25 publications

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“…Moreover, from the figure, it is observed that increasing the peak current increases the MRR. It is a common fact that increasing the current with no flow disturbance in the can produce the narrow power supply in the machining zone, which causes higher MRR [33]. The same trend of higher MRR has been obtained with the increasing of pulse on time and gap voltage.…”

Section: Fig 6 Influences Of Input Parameters On Mrrsupporting

confidence: 52%

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Saminatharaja¹,

Periyakgounder²,

Selvaraj³

et al. 2021

SV-JME

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Electrical discharge machines (EDM) are widely employed in machining components containing complex profiles of hard-to-cut and machining materials. However, the fabrication-of-tool time for the EDM process is excessively high in the traditional machining method, which significantly affects the machining rate. Therefore, in this paper, a powder metallurgy (PM) technique is employed to fabricate the tool electrode using copper (Cu), titanium carbide (TiC), and zirconium silicate (ZrSiO4) for different combinations. An L18 orthogonal array (OA) is planned using the following input parameters: three types of tools (Cu, Cu90, Cu80), peak current (PC) [A], pulse on time (PT) [µs], and gap voltage (GV) [V]. The performance of EDM is evaluated through the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The process parameters are optimized using two different techniques: the technique for order of preference by similarity to the ideal solution (TOPSIS) and grey relational analysis (GRA). TOPSIS and GRA optimization techniques produce the same optimal parametric solution for less TWR, SR, and higher MRR with the combination of the Cu90 tool, E8 APC, 15 µs pulse PT, and 75 V GV. Based on the ANOVA table of TOPSIS, pulse on time plays a major role, contributing 46.8 % of the machining performance; peak current shows the most significant contribution of 39.3 % of the machining performance using GRA values. Furthermore, the scanning electron microscope (SEM) image analyses are carried out on the machined workpiece surface to understand the effect of tools on machining quality.

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Section: Fig 6 Influences Of Input Parameters On Mrrsupporting

confidence: 52%

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Saminatharaja¹,

Periyakgounder²,

Selvaraj³

et al. 2021

SV-JME

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“…They created the curvatures in the electrode to increases the current density in the machining zone. Soundarrajan et al [21] studied the influence of different electrode coating on copper work material through EMM process. The length of the tool and coating thickness significantly affects the machining performances.…”

Section: Introductionmentioning

confidence: 99%

Enhancing MRR and accuracy with magnetized graphite tool in electrochemical micromachining of copper

Palaniswamy¹,

Seeniappan²,

Thanigaivelan

et al. 2023

CI&CEQ

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Micro hole is the fundamental feature found in any device/components. Hence this paper aims to produces the micro holes using electrochemical micromachining (EMM). The existing machining techniques in EMM for creating micro holes are associated with more overcut (OC). Hence, it is very essential to reduce OC and enhance the machining rate (MR). This paper aspires to investigate the effect of graphite electrode with magnetic force on copper plate. Four different tools namely electromagnetic graphite tool (EMGT), permanent magnet graphite tool (PMGT), graphite tool and stainless steel (SS) tool are employed for these experiments. The major influencing factors are machining voltage in volts, duty cycle in % and electrolyte concentration in g/l was considered on MR and OC. The results exposed that EMGT, PMGT and graphite electrodes produce MR of 106.4%, 74.6 % and 44.5 % over SS tool at parameter level of 23 g/l, 15 V, and 85% respectively. Graphite and EMGT electrode resulting in 11.9% and 3.41 % reduced OC respectively than SS tool at parameter level of 8V, 95% and 28 g/l. Additionally, scanning electron microscope (SEM) picture examination is conducted to identify the magnetic field effect on the work surface.

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“…The electrochemical micromachining has various advantages and visible limitations are stray cut. Research on reducing the stray cut is reported by various researchers such as applying epoxy resin, electroplating of nickel and chromium, spin-coating, polytetrafluoroethylene and ceramic coated tools [1][2][3][4][5][6]. In this research the research the ceramic coated electrode is considered to machine copper plate in sodium nitrate electrolyte.…”

Section: Introductionmentioning

confidence: 99%

Effect of Ceramic Coated Tool on Stray Cut in Electrochemical Micromachining

Yuvaraj,

Anusha,

Sri

et al. 2023

JNMES

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Electrochemical micromachining (ECMM) is an important machining process for machining materials susceptible to produce burrs during contact machining process. In this research copper plate of thickness 2mm and tool electrode of 464μm were machined through ECMM process under the sodium nitrate electrolyte (NaNO3).The tool electrode is coated with ceramic material and prevent stray current and chemical attack. The control factors namely, voltage, electrolyte concentration and duty cycle are varied on machining time and overcut. Higher voltage of 12V takes 1 minute to complete the through hole and the use of ceramic coated tool produces good arc on the circumference of the micro-hole and 65% reduction of overcut. The suitable range of electrolyte concentration for reduced machining time is 24 to 26g/lit. As per TOPSIS analysis, 10V, 24g/lit and 65% duty cycle and 11V, 24g/lit and 75% are the best optimal combinations. ANOVA results show that voltage and electrolyte concentration are the most significant factors with 57.73% and 28.83% contribution, respectively

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Effect of coated and geometrically modified tools on performance of electrochemical micromachining

Cited by 19 publications

References 25 publications

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Enhancing MRR and accuracy with magnetized graphite tool in electrochemical micromachining of copper

Effect of Ceramic Coated Tool on Stray Cut in Electrochemical Micromachining

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