Multiple Parameter Optimization by Wire Electrochemical Discharge Machining Process on Quartz Glass

Abstract

The hard, brittle, and electrically non-conducting industrial materials like quartz glass pose a challenge in the field of conventional machining. Even some electrically assisted non-conventional machining methods find difficulty to develop features on such materials owing to their non-conducting nature. Microslots are developed on quartz glass slices through Wire electrochemical discharge machining process using zinc-coated brass wire with 0.1 mm diameter. The chemical reactions involved in this process are presented. The slots are obtained employing NaOH electrolyte solution. Minitab software is used to form a DOE to obtain material removal rate and width of cut as output responses and varying the combination of voltage, electrolyte concentration, wire speed, and interelectrode gap. Using Taguchi's technique in the software, the significant factors, their level of significance, and their optimal combination to obtain superlative responses are determined. The surface texture of machined slots obtained for each experiment performed is observed through optical microscopic images. Analysis of experiment results demonstrate that the slots obtained using NaOH electrolyte solution have curved edge with smooth wall texture.