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Innovative study of electro chemical discharge drilling of silica based BK7 optical glass

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Abstract

Machining achievements of advanced non-conductive materials have challenged researchers to make it feasible to use them for manufacturing purposes. Electrochemical discharge drilling (ECDD) is an advanced hybrid process in the field of unconventional machining process that promotes difficult-to-cut hard and brittle materials. In this study, the effect of various input factors like applied voltage, electrolyte concentration, pulse-on time, and P-off time was considered to find their influence on performance parameters, i.e., material removal rate (MRR) and radial overcut (ROC). The experiments were conducted while drilling BK7 glass materials on an in-house developed ECDD setup. From experiments, it has been found that when increases the applied voltage and pulse are on time, the MRR and ROC increase, and also increase in P-off time decrease in MRR & ROC was observed. Simultaneously, it has been found that when the voltage reached (above 45 V) beyond the particular value, cracks phenomena and significant heat affected zone (HAZ) formed in the apex top surface of the workpiece. The effect was evaluated by scanning electron microscopy (SEM). Further, For MRR, the electrolytic concentration is the main influential and significant parameter with a 61.61% contribution, and for overcut, the DC voltage is the most significant parameter with a 72.33% contribution at a 95% confidence interval.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad, Jharkhand, 826004, India

    R. Saxena, A. Mandal & S. Chattopdhyay

  2. Department of Computer Sciences and Engineering, Institute of Advanced Research, The University for Innovation, Gandhinagar, Gujarat, 382426, India

    Ankit D. Oza

  3. Department of Mechanical Engineering, Chandigarh University, Gharuan, 140413, Punjab, India

    Manoj Kumar

  4. Division of Research and Innovation, Uttaranchal University, Dehradun, Uttarakhand, 248007, India

    Kumar Ashutosh

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  1. R. Saxena
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Saxena, R., Mandal, A., Chattopdhyay, S. et al. Innovative study of electro chemical discharge drilling of silica based BK7 optical glass. Int J Interact Des Manuf 17, 2461–2471 (2023). https://doi.org/10.1007/s12008-022-01029-2

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  • DOI: https://doi.org/10.1007/s12008-022-01029-2

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