Title: Investigations on the effect of helical tool diameter assisted with high speed rotation in electrochemical discharge machining

Authors: Jinka Ranganayakulu; P.V. Srihari

Addresses: Department of Mechanical Engineering, RV College of Engineering®, Bengaluru 560-059, India ' Department of Mechanical Engineering, RV College of Engineering®, Bengaluru 560-059, India

Abstract: Machining of low machinable non conducting engineering materials like borosilicate glass has imposed challenges in the manufacturing of micro devices like microfluidics, MEMS etc. Electrochemical discharge machining (ECDM), a hybrid processes of electric discharge machining (EDM) and electro chemical machining (ECM), emerging as a potential method to address the low machinability problems. In the present work the influence of helical tungsten carbide tools of varying diameter assisted with high speed tool rotation was adopted to improve machining performance in terms of on the material removal rate (MRR), heat affected zone (HAZ), radial over cut (ROC), tool wear rate (TWR) and depth of machining (DOM). It was found that the hydrodynamic region was more predominant with tool diameters 600 μm, 700 μm and at 2,500 rpm and resulted to a low machining depth. Smaller diameter tools assisted with rotational was found significant influence on the machining responses.

Keywords: electrochemical discharge machining; ECDM; helical tool; material removal rate; MRR; heat affect zone; HAZ; depth of machining; DOM; radial over cut; ROC; tool wear rate; TWR.

DOI: 10.1504/IJPTECH.2021.116803

International Journal of Precision Technology, 2021 Vol.10 No.1, pp.60 - 73

Received: 12 Aug 2020
Accepted: 05 Oct 2020
Published online: 02 Aug 2021 *

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