Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification

Basak, Indrajit; Ghosh, Amitabha

doi:10.1016/s0924-0136(97)00097-6

Cited by 151 publications

(76 citation statements)

References 2 publications

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“…A non-conducting ceramic workpiece is placed in the closed vicinity of the electrical discharge, and the material of the workpiece is melted, vapourised and eroded due to the transmission of a fraction of spark energy to the workpiece. This raises the temperature of the region dramatically, and a part of the molten portion of the workpiece is removed due to the mechanical shock resulting from the sudden phase change and the electrical spark discharge [4][5][6][7]. Additional material removal also takes places due to thermal spalling [8,9].…”

Section: Introductionmentioning

confidence: 99%

Parametric analysis on electrochemical discharge machining of silicon nitride ceramics

Sarkar

Doloi

Bhattacharyya

2006

Int J Adv Manuf Technol

140

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The electrochemical discharge machining (ECDM) process has a potential in the machining of silicon nitride ceramics. This paper describes the development of a second order, non-linear mathematical model for establishing the relationship among machining parameters, such as applied voltage, electrolyte concentration and inter-electrode gap, with the dominant machining process criteria, namely material removal rate (MRR), radial overcut (ROC) and thickness of heat affected zone (HAZ), during an ECDM operation on silicon nitride. The model is developed based on response surface methodology (RSM) using the relevant experimental data, which are obtained during an ECDM micro-drilling operation on silicon nitride ceramics. We also offer an analysis of variance (ANOVA) and a confirmation test to verify the fit and adequacy of the developed mathematical models. From the parametric analyses based on mathematical modelling, it can be recommended that applied voltage has more significant effects on MRR, ROC and HAZ thickness during ECDM micro-drilling operation as compared to other machining parameters such as electrolyte concentration and inter-electrode gap.Keywords ANOVA 9 Micro-electrochemical discharge machining (ECDM) 9 Response surface methodology (RSM) 9 Silicon nitride

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Section: Introductionmentioning

confidence: 99%

Parametric analysis on electrochemical discharge machining of silicon nitride ceramics

Sarkar

Doloi

Bhattacharyya

2006

Int J Adv Manuf Technol

140

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“…4, the total cycle time can be expressed as a sum of pulse-on time or arcing period (t a ) and pulse-off time or idle time (t i ) which is given by (1).…”

Section: Ic4m and Icdes 2017mentioning

confidence: 99%

“…Due to sudden ohmic heating, some of the bubble bridges blow off, thereby opening the circuit quickly. This switching-off action [1] causes a sudden fluctuation in current thereby inducing an e.m.f. This will cause ionization of the gas inside the bubble and a discharge will be produced.…”

Section: Introductionmentioning

confidence: 99%

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A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

Ladeesh

Manu

2017

MATEC Web Conf.

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Abstract. Grinding aided electrochemical discharge machining is a hybrid technique, which combines the grinding action of an abrasive tool and thermal effects of electrochemical discharges to remove material from the workpiece for producing complex contours. The present study focuses on developing fluidic channels on borosilicate glass using G-ECDM and attempts to develop a mathematical model for surface roughness of the machined channel. Preliminary experiments are conducted to study the effect of machining parameters on surface roughness. Voltage, duty factor, frequency and tool feed rate are identified as the significant factors for controlling surface roughness of the channels produced by G-ECDM. A mathematical model was developed for surface roughness by considering the grinding action and thermal effects of electrochemical discharges in material removal. Experiments are conducted to validate the model and the results obtained are in good agreement with that predicted by the model.

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“…The model, however, does not predict the critical resistance and neglects its effect on the process. Nevertheless, this model has been used reasonably to predict the material removal rates of ECDM performed with different electrolytes and concentrations [12]. It puts forth a theory that the material removal rate of the process can be increased by increasing the inductance in the circuit.…”

Section: Literature Reviewmentioning

confidence: 99%

A mathematical model to predict overcut during electrochemical discharge machining

Kamaraj

Jui

Cai

et al. 2015

Int J Adv Manuf Technol

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Overcut is a major reason for the dimensional deviations, especially during high aspect ratio micromachining in electrochemical discharge machining (ECDM). Since electrolyte concentration plays a vital role in material removal, by understanding the effect of electrolyte concentration on the machined feature, it is possible to reduce the overcut associated with the ECDM process. This reduction in overcut was used in the study to drill high aspect ratio microholes in glass. The effect of concentration on the overcut is explained with an analytical model. The model considers the thermal effects on material removal for ECDM assuming a high-temperature chemical etching mechanism for the material removal. It describes the effect of electrolyte concentration as well as machining time on material removal. Results reveal that at the microscale, tool diameter has minimal effect on overcut for a given machining voltage. Microholes with aspect ratios as high as 12 were produced in glass in this study.

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Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification

Cited by 151 publications

References 2 publications

Parametric analysis on electrochemical discharge machining of silicon nitride ceramics

Parametric analysis on electrochemical discharge machining of silicon nitride ceramics

A mathematical model for surface roughness of fluidic channels produced by grinding aided electrochemical discharge machining (G-ECDM)

A mathematical model to predict overcut during electrochemical discharge machining

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