Integrity of surfaces produced by electrochemical machining

Osman, Haidy M.; Abdelrahman, Mostafa H.

doi:10.1016/0924-0136(93)90126-q

Cited by 14 publications

(3 citation statements)

References 5 publications

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“…High SR is found at low machining voltage due to unsteady and non-uniform metal dissolution at the anode surface. 34 It may also be observed that little metal was removed with some thin grinding traces that reveal crystallographic steps and etch pits resulting in higher SR. With increasing applied voltage, these pits are gradually overlapped to each other due to uniform metal dissolution by increasing the current density in the machining zone. Thus, finer and flatter SR is observed with high voltage that can be shown in Figure 7(a).…”

Section: Resultsmentioning

confidence: 99%

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Rahi

Dubey

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Hybrid metal matrix composites have superior strength to weight ratio as compared with conventional composites or superalloys. This characteristic makes them suitable for different advanced industries such as aerospace, automobile, and biomedical. Mechanical and thermal energy based processes have their own limitations to machine these composites due to superior mechanical properties and melting of reinforcement particles, respectively. Researchers are trying to machine metal matrix composites by the electrochemical process with the aim to achieve better machining quality, but low material removal rate and oxide layer formation on the machined surface has emerged as the main limitation. A hybrid variant of electro-chemical machining (ECM) and conventional grinding has capability to overcome these limitations. Keeping this in view, the experimental set-up of electro-chemical surface grinding (ECSG) has been developed with the aim to compare the machining characteristics of the hard-to-cut hybrid metal matrix composite Al–SiC–Gr with the ECM process. The machining performances have been compared on the basis of material removal rate, surface roughness, and microcrack width in the machined component. The influence of some important input process parameters on these performance characteristics have been analyzed scientifically. Experimental results show that the ECSG process improves the machining performance by reducing or eliminating the oxide layer from the machining zone due to suitable grinding effects. Material removal rate, surface roughness, and microcrack width were improved by 68%, 24%, and 40%, respectively, by using the ECSG process. The formation of the large size oxide layer with high crack width on the machined surface was observed at high voltage, high electrolyte concentration, and at low table speed.

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Section: Resultsmentioning

confidence: 99%

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Rahi

Dubey

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…26(a) shows that at low voltage and feed rate surface roughness is higher. This is because of unsteady and non-uniform in anodic metal dissolution (Osman and Abdel-Rahman 1993). At low current density surface etchings reveals etch pits and preferred grain boundary is attacked which cause uneven microstructure leading to rougher surface.…”

Section: Materials Removal Ratementioning

confidence: 99%

Developments in the non-traditional machining of particle reinforced metal matrix composites

Pramanik¹

2014

International Journal of Machine Tools and Manufacture

154

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The non-traditional machining of particulate reinforced metal matrix composites is relatively new. However, researchers seem to pay more attention in this field recently as the traditional machining of particulate reinforced metal matrix composites is very complex. This research investigates different non-traditional machining, such as electro-discharge, laser beam, abrasive water jet, electro-chemical and electro-chemical discharge machining of this composite materials. The machining mechanism, material removal rate/machining speed and surface finish have been analysed for every machining process. This analysis clearly shows that vaporisation, melting, chemical dissolution and mechanical erosion are the main material removal mechanism during non-traditional machining. The thermal degradation and presence of reinforcement particles mainly damage the machined surface. The understanding on electro-discharge, laser beam and abrasive water jet machining are more developed than that of electro-chemical and electro-chemical discharge machining for particulate reinforced MMC.1 Developments in the non-traditional machining of particle reinforced metal matrix composites AbstractThe non-traditional machining of particulate reinforced metal matrix composites is relatively new.However, researchers seem to pay more attention in this field recently as the traditional machining of particulate reinforced metal matrix composites is very complex. This research investigates different non-traditional machining, such as electro-discharge, laser beam, abrasive water jet, electro-chemical and electro-chemical discharge machining of this composite materials. The machining mechanism, material removal rate/machining speed and surface finish have been analysed for every machining process. This analysis clearly shows that vaporisation, melting, chemical dissolution and mechanical erosion are the main material removal mechanism during non-traditional machining. The thermal degradation and presence of reinforcement particles mainly damage the machined surface. The understanding on electro-discharge, laser beam and abrasive water jet machining are more developed than that of electro-chemical and electro-chemical discharge machining for particulate reinforced MMC.

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“…However, most researchers have focused attention on the machining gap between the electrodes or the width of the machined grooves, regardless of the machining surface integrity. Studies on surface integrity in macro electrochemical machining (ECM) have been carried out, and the effect of various process parameters on surface integrity has been studied (Osman and Abdel-Rahman, 1993). A response surface methodology based mathematical model has been adopted to optimize various input parameters for achieving a high material removal rate and accuracy (Bhattacharyya and Sorkhel, 1999).…”

Section: Introductionmentioning

confidence: 99%

Study of surface roughness in wire electrochemical micro machining

Zeng

et al. 2015

Journal of Materials Processing Technology

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Integrity of surfaces produced by electrochemical machining

Cited by 14 publications

References 5 publications

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Developments in the non-traditional machining of particle reinforced metal matrix composites

Study of surface roughness in wire electrochemical micro machining

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