Investigations on performance of ECDM process using different tool electrode while machining e-glass fibre reinforced polymer composite

Saini, Gaurav; Manna, Alakesh; Sethi, Amanpreet Singh

doi:10.1016/j.matpr.2020.04.853

Cited by 10 publications

(5 citation statements)

References 16 publications

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“…Tool electrodes and auxiliary electrodes are important in ECDM [23][24][25], and the material choice for them should be carefully considered. The tool electrode should not only have good electrical conductivity, but also needs to withstand the high temperature of electric spark discharge and strong alkali corrosion.…”

Section: Methodsmentioning

confidence: 99%

An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material

et al. 2020

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Electrochemical discharge machining (ECDM) and laser machining are emerging nontraditional machining technologies suitable for micro-processing of insulating and hard-brittle materials typified by glass. However, poor machinability of glass is a major constraint, which remains to be solved. For the micro-grooves processed by ECDM, the bottom surface is usually uneven and associated with protrusion structures, while the edges are not straight with obvious wave-shaped heat-affected zones (HAZs) and over-cutting. Besides, the cross section of the micro-grooves processed by the laser is V-shape with a large taper. To solve these problems, this study proposed the laser-assisted ECDM for glass micro-grooving, which combines ECDM and laser machining. This study compared morphological features of the single processing method and the hybrid processing method. The results show that ECDM caused cylindrical protrusions at the bottom of the microgrooves. After processing these micro-grooves by laser, the cylindrical protrusions were removed. However, the edge quality of the microgrooves was still poor. Therefore, we used the laser to get microgrooves first, so we got micro-grooves with better edge quality. Then we use ECDM to improve the taper of microgrooves and the cross-sectional shape of the microgrooves transformed from a V-shape to a U-shape.

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Section: Methodsmentioning

confidence: 99%

An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material

et al. 2020

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“…Higher IEG increases the resistance between electrodes, which reduces electrolyte conductivity [86] and spark-assisted zone [87], which results in reduced MRR. A study by Saini et al [88] shows that MRR increases with an increase in IEG up to a certain level and then reduces due to higher resistance and reduced discharge sparks. Effect of variations in IEG and tool-substrate gap on various machining parameters is outlined in table 2.…”

Section: Inter Electrode Gap and Tool-substrate Gapmentioning

confidence: 99%

“…Reduction in MRR, while increasing pulse off time, have been found least in brass tool. Due to lower conductivity of brass, less heat is dissipated from tool [88].…”

Section: Tool Materialsmentioning

confidence: 99%

A review on micro-drilling by electrochemical discharge machining

2023

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The electrochemical discharge machining (ECDM) process is a hybrid of electric discharge machining and electrochemical machining. It was developed to overcome the limitations of other machining technologies on the micromachining of non-conducting materials. The performance of the process depends on various parameters. In this review article, the implications of input parameters on machining performance have been covered in detail. It is observed that various input parameter levels give different rate and quality of machining. A higher applied voltage and electrolyte concentration give a higher material removal rate but has adverse effects such as overcutting and heat-affected zone. The optimum process parameters for better material removal rate and surface quality have been discussed. The ECDM technique has undergone numerous modifications to meet various machining needs. The main ECDM process variants have been thoroughly examined. A wide variety of non-conducting materials, including glass, ceramics, and reinforced composites, have been successfully machined using the ECDM technique. The applications of the ECDM process have been examined and addressed. Potential future research directions and present advancements have also been presented.

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“…The investigation reveals that brass is the most efficient electrode material. 81 In the ECDM procedure, a comparison is made between the micro-grooves tool electrode and the side-insulated tool electrode with micro-grooves and a 4-µm diamond coating. The investigation result showed that no noticeable heat affected zone and etching at the entrance and the hole with good surface integrity obtained by side-wall insulated tool electrode, while the micro-groove tool has a HAZ width of 2–4 µm.…”

Section: Parametersmentioning

confidence: 99%

Process capability of electrochemical discharge machining: A review

Prakash,

Kumar,

Ballav

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Electrochemical discharge machining (ECDM) is a hybrid machining formed by combining the principles of electrochemical machining and electrical discharge machining. The ECDM is unconventional micromachining that can fabricate holes, blind holes, micro-cavities and grooves on brittle insulating materials such as quartz, glass, silicon wafers and different composites that are difficult to machine. These non-conducting materials have sundry applications such as Micro Electric-Mechanical Systems, biomedical and electronics items. The ECDM provides maximum material removal rate and good surface quality with minor tool wear. The study describes how different process parameters affect machining. The assessment mainly focuses on various tool electrode geometries and materials that are used in ECDM. The present article investigates the ramifications of different types of electrolytes and additives mixed in electrolytes used during the ECDM process on the machined zone. This paper comprehensively reviews the effect of change in applied voltage, machining gap and an inter-electrode gap in the ECDM and it also analyses the fabrication of different materials including glass, quartz, ceramics and composites.

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Investigations on performance of ECDM process using different tool electrode while machining e-glass fibre reinforced polymer composite

Cited by 10 publications

References 16 publications

An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material

An Investigation into Laser-Assisted Electrochemical Discharge Machining of Transparent Insulating Hard-Brittle Material

A review on micro-drilling by electrochemical discharge machining

Process capability of electrochemical discharge machining: A review

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