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Enhancement of Electrochemical Discharge Machining (ECDM) Characteristics with Tool Electrode Rotation

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Advances in Modelling and Optimization of Manufacturing and Industrial Systems

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

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Abstract

Electrochemical discharge machining (ECDM) process is a novel process that utilizes the mechanism of thermal melting and chemical dissolution to machine the non-conductive materials. The occurrence of poor micro-hole machining characteristics in gravity-assisted tool feed is one of the challenges in ECDM process. The physical contact of the tool electrode with the work material results in ineffectual electrolyte availability, poor electrolyte flushing and non-uniform sparks. The present study attempts an experimental investigation for enhancing the micro-hole characteristics with the application of tool electrode rotational effect. Material removal rate (MRR), hole circularity (HC), radial overcut (ROC), and heat-affected zone (HAZ) are selected as a response characteristic. The microscopy images emphasized that tool electrode rotation substantially improved the machining characteristic of the micro-holes when compared to characteristic obtained without the tool rotation. Tool electrode rotation helps in replenishment of electrolyte flushing and enables better consistencies of spark distribution. It is concluded that the tool electrode rotation produces micro-holes with better hole circularity compared to stationary tools that produces poor hole circularity. Further, an improvement of 25.21% in MRR and 44.4% in ROC is obtained with the application of tool electrode rotation. The present study successfully describes the enhancement of ECDM characteristics with tool electrode rotation.

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Abbreviations

μm:

Microns

V:

Applied voltage unit in volts

wt%:

Weight percentage of electrolyte concentration

mg/min:

Milligram per minute

wtb:

Work material weight before machining

wta:

Work material weight after machining

t :

Time

g:

Weight unit in grams

D ent :

Hole entrance diameter

d :

Tool diameter

MEMS:

Micro-electro-mechanical systems

ECM:

Electrochemical machining

EDM:

Electric discharge machining

ECDM:

Electrochemical discharge machining

MRR:

Material removal rate

HAZ:

Heat-affected zone

ROC:

Radial overcut

HC:

Hole circularity

IEG:

Inter-electrode gap

NaOH:

Sodium hydroxide

3D:

Three-dimensional

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Authors and Affiliations

  1. Department of Production and Industrial Engineering, Punjab Engineering College, Chandigarh, India

    Viveksheel Rajput, Mudimallana Goud & Narendra Mohan Suri

Authors
  1. Viveksheel Rajput
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  2. Mudimallana Goud
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  3. Narendra Mohan Suri
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Corresponding author

Correspondence to Viveksheel Rajput .

Editor information

Editors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, Haryana, India

    Ravi Pratap Singh

  2. Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, Haryana, India

    Mohit Tyagi

  3. Department of Production and Industrial Engineering, Punjab Engineering College, Chandigarh, India

    R. S. Walia

  4. Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

    J. Paulo Davim

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Rajput, V., Goud, M., Suri, N.M. (2023). Enhancement of Electrochemical Discharge Machining (ECDM) Characteristics with Tool Electrode Rotation. In: Singh, R.P., Tyagi, M., Walia, R.S., Davim, J.P. (eds) Advances in Modelling and Optimization of Manufacturing and Industrial Systems. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-19-6107-6_11

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  • DOI: https://doi.org/10.1007/978-981-19-6107-6_11

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  • Online ISBN: 978-981-19-6107-6

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