Title: Process modelling and investigations in to the electrochemical discharge drilling of soda-lime-silica-glass

Authors: B. Nithin; V.G. Ladeesh; T. Aneesh; R. Manu

Addresses: Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, 673601, Kerala, India ' Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, 673601, Kerala, India ' Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, 673601, Kerala, India ' Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, 673601, Kerala, India

Abstract: Electro-chemical discharge machining (ECDM) is a hybrid non-conventional machining process that combines the features of electro chemical machining (ECM) and electro discharge machining (EDM). ECDM is an effective micro-machining process for non-conducting materials like glass, ceramics, composites, quartz, etc. The present study attempts to analyse the effects of process parameters including applied voltage, electrolyte concentration, frequency and duty factor on material removal rate (MRR). A widely used response surface design called Box-Behnken design was used to conduct the experiments. From the analysis of variance, significant factors that contribute MRR can be ranked in the descending order of duty factor, frequency and voltage. The effect of electrolyte concentration is found to be insignificant. A strong interaction between duty factor and frequency is identified in controlling MRR. From the microscopic images of the machined surface, thermal spalling is identified as a significant mechanism for material removal along with thermal melting and chemical etching.

Keywords: electro-chemical discharge machining; ECDM; Box-Behnken design; material removal rate; MRR.

DOI: 10.1504/IJASMM.2017.089931

International Journal of Additive and Subtractive Materials Manufacturing, 2017 Vol.1 No.3/4, pp.360 - 371

Received: 18 Apr 2017
Accepted: 08 Nov 2017
Published online: 25 Feb 2018 *

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