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A strategy to improve performance in electrochemical discharge machining using periodic bi-directional tool rotation

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Abstract

Increasing machining depth has imposed challenges to machine high aspect ratio features in electrochemical discharge machining (ECDM) of hard and brittle materials like borosilicate glass. As depth of machining (DOM) progresses, the machining is slowed due to insufficient availability of electrolyte at the tool tip. The stagnated electrolyte at the entrance of the hole causes increased radial overcut (ROC), heat-affected zone (HAZ), and taper (TP) and also reduced material removal rate (MRR), DOM, and circularity (CR). To overcome these challenges, the present study implemented a novel strategy using periodic bi-directional tool rotation (PBTR) with tungsten carbide helical drill. Initially, a flow simulation with KOH electrolyte has been conducted using COMSOL multi-physics platform to understand effect of the tool rotation on machining characteristics for both unidirectional tool rotation (UTR) and PBTR. It is found from the simulation that the PBTR shows better electrolyte supply to the tool tip as compared to UTR. Experiments are conducted with experimental plan based on L16 array. Experimental results disclosed that PBTR has resulted an improvement in MRR, DOM, and circularity and a decrease in HAZ, ROC, and TP of the machined hole. Parametric optimization is carried out using teaching learning-based optimization (TLBO) algorithm to evaluate the optimum process parameters. Optimum values are confirmed with by the experimental results.

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Funding

Authors received support from the Vision Group on Science & Technology, KSTePS, Department of IT, BT and S&T, Karnataka – 560 001, through KFIST Level (1) project under the VGST Scheme, No: KSTePS/VGST/GRD-678/KFIST(L1)/2018, 27.08.2018.

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Authors and Affiliations

  1. Department of Mechanical Engineering, RV College of Engineering, Bengaluru, India, 560059

    Jinka Ranganayakulu & Podala Venkata Srihari

  2. Department of Mechanical Engineering, Vignan’s Foundation for Science, Technology and Research, Vadlamudi, Andhra Pradesh, India, 522213

    Kaki Venkata Rao

Authors
  1. Jinka Ranganayakulu
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  2. Podala Venkata Srihari
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  3. Kaki Venkata Rao
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Contributions

Mr. Jinka Ranganayakulu and Dr. Podala Venkata Srihari have designed the experimental plan and carried out the experimentation. They also involved in analysis and preparation of manuscript. Dr. Kaki Venkata Rao have involved in analysis and optimization of process parameters.

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Correspondence to Kaki Venkata Rao.

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Ranganayakulu, J., Srihari, P.V. & Rao, K.V. A strategy to improve performance in electrochemical discharge machining using periodic bi-directional tool rotation. Int J Adv Manuf Technol 123, 1459–1476 (2022). https://doi.org/10.1007/s00170-022-10227-x

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