Experimental investigation on electrochemical grinding (ECG) of alumina-aluminum interpenetrating phase composite

The present paper focuses on the evaluation of material removal rate (MRR), surface finish, and cutting forces during electrochemical grinding of Al₂O₃/Al interpenetrating phase composite. The effect of electrolyte concentration, supply voltage, depth of cut, and electrolyte flow rate on machining performances has been studied. The characteristic features of the electrochemical grinding (ECG) process are explored through Taguchi-design-based experimental studies with various process parametric combinations and finally the process has been optimized. The mechanism of material removal and surface characteristics under different grinding conditions have been studied through SEM micrograph. Besides, another set of experimental investigation has been carried out in order to identify the influence of different type of electrolytes and degree of reduction in grinding force in ECG. Finally, a comparative study of conventional and electrochemical grinding of this special class of material has been carried out.