Title: Innovations in electro chemical discharge machining process through electrolyte stirring and tool rotations

Authors: C.S. Jawalkar; Apurbba Kumar Sharma; Pradeep Kumar

Addresses: Department of Production and Industrial Engineering, Punjab Engineering College (Deemed to be University), Chandigarh, 160012, India ' Department of MIED, Indian Institute of Technology Roorkee, Roorkee 247667, India ' Department of MIED, Indian Institute of Technology Roorkee, Roorkee 247667, India

Abstract: Electro chemical discharge machining (ECDM) process is gaining considerable importance in micro-machining of non-conductive and brittle materials like glass and ceramics. Recently it has undergone some innovations in the form of hybrid and variant processes, which have been reviewed and discussed in this paper. To further aid developments, an innovative hybrid process combining electrolyte-stirring and tool-rotation effect has been experimented and reported in this paper. The study was carried out in a phased manner on an in-house fabricated setup using Taguchi's orthogonal array L₁₈. The experimental results illustrate an improvement in the process as compared to normal ECDM (without using electrolyte stirring and tool rotations). The optimum value for material removal was 1.282 mg/min and surface finish (R_a) was 0.4 μm. The images obtained through field emission scanning electron microscopy (FESEM) illustrate useful insights into the process. A regression equation has also been developed for the process. The innovative hybrid process has bright prospects from process enhancement and economic point of view.

Keywords: rotary tool; electrolyte stirring; material removal; surface finish.

DOI: 10.1504/IJMMM.2020.111354

International Journal of Machining and Machinability of Materials, 2020 Vol.22 No.6, pp.487 - 503

Received: 05 Jun 2019
Accepted: 15 Jan 2020
Published online: 23 Nov 2020 *

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