Title: Systematic experimental analysis of electrochemical discharge machining process

Authors: Anjali V. Kulkarni

Addresses: NL-312, Centre for Mechatronics, ME Department, Indian Institute of Technology, Kanpur, Kanpur-208016, India

Abstract: A systematic qualitative and quantitative analysis of electrochemical discharge machining (ECDM) process through experimental investigations is presented. In situ, transient measurement of temperature (remotely sensed by pyrometer, at discharge striking zone) synchronised with online process current have been performed. These synchronised measurements have led to qualitative formulation of the discharge formation and material removal mechanisms. Two verities of K-type are used to sense the temperature at workpiece surface and temperature of electrolyte in the ECDM cell. With the online and post process measurements, quantitative analysis of the process is performed in terms of energy density striking the surface, geometry of discharge-affected (striking) region, metal removal rate (MRR), energy associated with major process components and efficiency of the process. Energy density associated with a single discharge is experimentally determined. Capability of single discharge has been explained for utilisation of ECDM process for micromachining.

Keywords: systematic experimental analysis; electrochemical discharge machining; ECDM; qualitative analysis; quantitative analysis; in situ measurements; pyrometer; discharge-affected region; discharge formation mechanism; material removal rate; MRR; energy analysis; energy density; micromachining; synchronised measurements.

DOI: 10.1504/IJMMM.2009.027324

International Journal of Machining and Machinability of Materials, 2009 Vol.6 No.3/4, pp.194 - 212

Published online: 20 Jul 2009 *

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