Investigation into electrochemical micromachining (EMM) through response surface methodology based approach |
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Authors: | Jagannath Munda Bijoy Bhattacharyya |
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Affiliation: | (1) Jadavpur University, Kolkata, West Bengal, India |
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Abstract: | Electrochemical micromachining (EMM) could be used as one the best micromachining technique for machining electrically conducting,
tough and difficult to machine material with appropriate machining parameters combination. This paper attempts to establish
a comprehensive mathematical model for correlating the interactive and higher-order influences of various machining parameters,
i.e. machining voltage pulse on/off ratio, machining voltage, electrolyte concentration, voltage frequency and tool vibration
frequency on the predominant micromachining criteria, i.e. the material removal rate and the radial overcut through response
surface methodology (RSM), utilizing relevant experimental data as obtained through experimentation. Validity and correctiveness
of the developed mathematical models have also been tested through analysis of variance. Optimal combination of these predominant
micromachining process parameters is obtained from these mathematical models for higher machining rate with acuuracy. Considering
MRR and ROC simultaneously optimum values of predominant process parameters have been obtained as; pulse on/off ratio, 1.0,
machining voltage, 3 V, electrolyte concentration, 15 g/l, voltage frequency of 42.118 Hz and tool vibration frequency as
300 Hz. The effects of various process parameters on the machining rate and radial overcut are also highlighted through different
response surface graphs. Condition of machined micro-holes are also exhibited through the SEM micrographs in this paper. Pulse
voltage pattern during electrochemical micromachining process has been analyzed with the help of voltage graphs. Irregularities
in the nature of pulse voltage pattern during electrochemical micromachining have been observed and the causes of these irregularities
are further investigated. |
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Keywords: | Electrochemical micomachining (EMM) Metal removal rate (MRR) Radial overcut (ROC) Response surface methodology (RSM) |
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