Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

Behroozfar, Ali; Razfar, Mohammad Reza

doi:10.1080/10426914.2015.1058951

Cited by 46 publications

(12 citation statements)

References 21 publications

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“…Then ultra-sonication of the mixture was performed for 3 h to maintain the uniform dispersion of the particles. Based on the literature [25][26][27], three input parameters, namely voltage (V), duty cycle (D), and electrolyte concentration of the working solution (C), were considered for this study.…”

Section: Materials Specificationsmentioning

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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Section: Materials Specificationsmentioning

confidence: 99%

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

2022

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“…Behroozfar and Razfar [29] presented a FEM based thermophysical model for characteristics of plasma channel and material removal in ECDM of soda lime glass. The plasma channel's mean diameter was reported as 260 µm based on spark signatures.…”

Section: Studies On Miscellaneous Parametersmentioning

confidence: 99%

“…Various material removal criteria were used by different researchers,which are tabulated in Table 6. [27] 2011 Krotz et al [28] 2013 Jiang et al [19] 2014 Kamraj et al [16] 2015 Behroozfar and Razfar [29] 2016 Paul and Korah [20] 2016 Kolhekar and Sundaram [25] 2019…”

Section: Simulation Approaches and Parametersmentioning

confidence: 99%

A Comprehensive Review on Modeling and Simulation Studies in Electro-Chemical Discharge Machining

Sharma¹,

Gupta²,

Kumar³

2022

New Frontiers in Communication and Intelligent Systems

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Glass has wide application in the production of micro components. Electro-chemical discharge machining (ECDM) has proven an inexpensive and potential micromachining method for such nonconductive materials. ECDM has the electro-chemical machining (ECM) and electric discharge machining (EDM) constituent processes. It overcomes limitations and provides benefits of both constituent processes, namely EDM and ECM. The major limitation in the industrial application of this technique is controlling of gas film formation and discharge activity. Researchers have attempted numerous studies, both experimental and simulation, exploring the physics behind the process. In view of appraising research carried out in recent years, the present work reports a comprehensive review of modeling and simulation studies in electro-chemical discharge machining along with a brief introduction to ECDM. Different modeling and simulation approaches applied by researchers were discussed. The importance of various simulation parameters and material removal criteria were justified.

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“…In this situation, chemical etching process is in dominating phase and machining highly depends on it. Behroozfar and Razfar 59 proposed that chemical etching is responsible for machining during ECSM process. They considered that simultaneous images of current signals are responsible for the shape of arc/discharge and a signature engraves on the workpiece.…”

Section: Ecsmmentioning

confidence: 99%

Electro-chemical spark machining–based hybrid machining processes: Research trends and opportunities

Yadav

2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Shaping of the difficult-to-machine non-conductive materials such as glass, quartz and ceramic is much difficult and uneconomical by existing machining processes. As a result, wide applicabilities of these materials are still limited. Even though these materials are highly required in the field of the modern industries. To overcome the problem, a new machining method has been proposed by researchers by combining the features of electro-chemical machining and electro-discharge machining. Such combined machining process is called as electro-chemical spark machining process. Such developed machining method becomes an appropriate process for machining of non-conductive materials with significant improvement in productivity as compared to the electro-discharge machining and electro-chemical machining processes. In this article, the role of electro-chemical spark machining for machining of the non-conductive materials has been summarized and focused on the future research possibilities in the same area. This article also focuses on mechanism, process and performance parameters, variants and new developments related to the electro-chemical spark machining. As a result, this review article becomes beneficial for researchers to understand the phenomena of the electro-chemical spark machining process as well as further development in the same area.

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Experimental and Numerical Study of Material Removal in Electrochemical Discharge Machining (ECDM)

Cited by 46 publications

References 21 publications

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

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

A Comprehensive Review on Modeling and Simulation Studies in Electro-Chemical Discharge Machining

Electro-chemical spark machining–based hybrid machining processes: Research trends and opportunities

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