Electrochemical Micromachining of Copper Alloy through Hot Air Assisted Electrolyte Approach

Soundarrajan, M.; Thanigaivelan, R.

doi:10.1134/s1023193521020117

Cited by 8 publications

(3 citation statements)

References 31 publications

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“…Kunar et al [9] have improved the accuracy of micro-hole by application of rectangular wave form voltage in EMM process on SS 304 work material with masked tool electrode. Soundarrajan et al [10] employed the hot air in EMM process to study the effect to electrolyte temperature on copper work material. They results reveal that the usage of citric acid for the copper work materials produce the non-conductive dissolved products which surround the tool and creates insulating effect on the tool for improving micro-hole accuracy.…”

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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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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“…An application of micro features such as micro square holes, micro grooves, taper surfaces, slots, micro holes and micro slits were increasing enormously in micro electromechanical systems (MEMS). Also due to the miniaturizations of electronic, medical, biomedical and automobile devices the micro machining plays significant role in manufacturing [1][2][3][4].The documented knowledge in EMM for generation micro features is archived for micro holes .In line with that, Pradeep et al [5] studied the performance of EMM using cryogenic treated graphite electrodes on SS 304. The use cryogenic treated tool shows good stray current protection and improves the accuracy of the micro-hole.…”

Section: Introductionmentioning

confidence: 99%

Performance study of electrochemical micromachining using square composite electrode for copper

T¹,

Perumal

Thanigaivelan³

2022

CI&CEQ

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The use of micro components is increasing day by day in the industries such as aviation, power circuit boards, inkjet nozzle and biomedical. Among various non-traditional micromachining methods, electrochemical micromachining (EMM) shows unique characteristics such as no tool wear, no residual stress and high accuracy. In this research EMM is considered to study the effect of square shaped stainless steel (SS) and aluminum metal matrix composite (AMC) tool on square hole generation. The significant process parameters such as machining voltage, duty cycle and aqueous sodium nitrate (NaNO3) electrolyte of varying concentration is considered for the study. The performances of EMM process are evaluated in terms of machining rate (MR) and Overcut (OC). The AMC tool shows 43.22 % lesser OC than the SS tool at the parameter combinations of 8V, 85% and 23 g/l. Also, for the same parameter combination MR for SS tool is 71.6 % higher than the AMC tool. Field emission scanning electron microscope image (FESEM) analysis shows that the micro square hole generated using composite electrode shows micro-pits on the circumference of the square hole. The energy dispersive X-ray spectroscopy (EDAX) analysis is conducted to verify presence and distributions of reinforcement in AMC tool.

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“…Very few researchers have investigated the heating of the machining zone, and no studies have investigated ultraviolet (UV)-and hot air (HA)-assisted conventional machining. These heating techniques, however, have been successfully used in other manufacturing sectors to improve the machining performance of non-traditional machining processes, such as biomedicine and electrical sectors [17][18][19][20]. In this study, UV and IR rays and HA are used to preheat a workpiece, and the results are compared with those obtained under non-heated machining conditions.…”

Section: Introductionmentioning

confidence: 99%

Performance optimisation of the turning process along with multi-surface heating process

Kumar¹,

Thanigaivelan

Natarajan³

2022

Materials Science-Poland

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Materials that are difficult to cut possess excellent qualities and machinability, though conventional machining techniques require additional energy to circumvent the problems associated with the turning process. In this study, heat-assisted turning of duplex stainless steel (SS) was carried out. Various heating techniques such as infrared (IR)-, ultraviolet (UV)- and hot air (HA)-assisted heating were adopted. The experiment used an L16 orthogonal array with the most significant parameters such as heating method, feed rate in millimetres per revolution (mm/rev), depth of cut (millimetres [mm]) and cutting speed (metres per minute [m/min])on the cutting force and surface roughness. The technique for order performance by similarity to ideal solution (TOPSIS) and grey relational analysis (GRA), were used to optimise the output performance. The results of TOPSIS showed that the 16th experimental combination, i.e., the HA heating method, with feed rate = 0.175 mm/rev, depth of cut = 0.1 mm and cutting speed = 150 m/min, required a smaller cutting force and resulted in lower surface roughness. In case of the GRA method, the best output performance was observed for the 15th experimental combination, that is, the HA heating method, with feed rate = 0.15 mm/rev, depth of cut = 0.2 mm and cutting speed = 200 m/min. Compared to the non–heat-assisted turning process, the HA- and UV-assisted processes required 10.25% and 7.69% lesser cutting force, respectively, and the surface roughness in case of the HA method was 15.13% lesser.

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Electrochemical Micromachining of Copper Alloy through Hot Air Assisted Electrolyte Approach

Cited by 8 publications

References 31 publications

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

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

Performance study of electrochemical micromachining using square composite electrode for copper

Performance optimisation of the turning process along with multi-surface heating process

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