The paper presents the result of an experimental investigation on the micro machining of electrically non-conductive e-glass–fibre–epoxy composite during electrochemical spark machining using specially designed square cross section with centrally micro hole brass tool and different diameter round-shaped micro tools made of IS-3748 steel. A micro electrochemical spark machining (ECSM) setup has been designed, fabricated and used for conducting the experiments. According to the Taguchi method-based design, the specific numbers of experiments have been carried out to investigate the influence of the fabricated ECSM parameters on the material removal rate and overcut on generated hole radius. Test results show that the material removal rate is maximum when machining was performed at higher setting value of D.C. supply voltage (e.g. 70 V), moderate setting value of electrolytic concentration (e.g. 80 g/l) and 180-mm gap between electrodes. Taking significant machining parameters into consideration and using multiple linear regression, mathematical modes for material removal rate and overcut on hole radius are established to investigate the influence of cutting parameters during micro-ECSM. The influence of machining parameters on machined hole and special shape contour quality are also analysed through different scanning electron micrographs. Confirmation test results established the fact that the developed mathematical models are appropriate for effectively representing the machining performance criteria.
This is a preview of subscription content, access via your institution.
Buy single article
Instant access to the full article PDF.
Price excludes VAT (USA)
Tax calculation will be finalised during checkout.
Jain VK, Dixit PM, Pandey PM (1999) On the analysis of the electrochemical spark machining process. Int J Mach Tool Manufact 39:165–186
Chak SK, Rao PV (2007) Trepanning of Al2O3 by electro-chemical discharge machining (ECDM) process using abrasive electrode with pulsed DC supply. Int J Mach Tool Manufact 47:2061–2070
Bhondwe KL, Yadava V, Kathiresan G (2006) Finite element prediction of material removal rate due to electro-chemical spark machining. Int J Mach Tool Manufact 46(14):1699–1706
Basak I, Ghosh A (1997) Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification. J Mater Process Tech 71(3):350–359
Jain VK, Choudhury SK, Ramesh KM (2002) On the machining of alumina and glass. Int J Mach Tool Manufact 42:1269–1276
Bhattacharyya B, Munda J (2003) Experimental investigation on the influence of electrochemical machining parameters on machining rate and accuracy in micromachining domain. Int J Mach Tool Manufact 43:1301–1310
Mediliyegedara TKKR, De SAKM, Harrison DK, McGeough JA (2005) New developments in the process control of the hybrid electro chemical discharge machining (ECDM) procss. J Mater Process Tech 167(2–3):338–343
Schöpf M, Beltrami I, Boccadoro M, Kramer D, Schumacher B (2001) ECDM (electro chemical discharge machining), a new method for trueing and dressing of metal bonded diamond grinding tools. CIRP Ann Manuf Technol 50(1):125–128
Han M-S, Min B-K, Lee Sang Jo (2007) Improvement of surface integrity of electro-chemical discharge machining process using powder-mixed electrolyte. J Mater Process Tech 191(1–3):224–227
Peng WY, Liao YS (2004) Study of electrochemical discharge machining technology for slicing non-conductive brittle materials. J Mater Process Tech 149:363–369
Bhattacharyya B, Munda J, Malapati M (2004) Advancement in electrochemical micro-machining. Int J Mach Tool Manufact 44:1577–1589
Montgomery DC (1997) Design and analysis of experiments. Wiley, New York
Rights and permissions
About this article
Cite this article
Manna, A., Narang, V. A study on micro machining of e-glass–fibre–epoxy composite by ECSM process. Int J Adv Manuf Technol 61, 1191–1197 (2012). https://doi.org/10.1007/s00170-012-4094-3
- E-glass–fibre–epoxy composite
- SEM photo