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Revolutionary Developments in ECDM Process: An Overview
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 2 (2015) 3188 – 3195
4th International Conference on Materials Processing and Characterization
Revolutionary Developments in ECDM Process: An Overview PravinPawara*, Raj Ballavb, Amaresh Kumarc a
Ph.D Research Scholar , Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur,831014,India b,c Associate Professor, Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur,831014,India
Abstract This paper shows a review on ECDM process on the basis of Novel theoretical model, novel process, and novel machine design © 2014Published The Authors. Elsevier © 2015 by Elsevier Ltd.Ltd. All rights reserved. Selection andpeer-review peer-review under responsibility ofconference the conference committee members ofInternational the 4th International on Selection and under responsibility of the committee members of the 4th conferenceconference on Materials ProcessingProcessing and Characterization. Materials and Characterization. Keywords: Electro chemical discharge machining
1. Introduction Electro chemical discharge machining (ECDM) is a hybrid non-conventional manufacturing process which combines the features of electro chemical machining (ECM) and electro discharge machining (EDM) [3][4][10][11] [13]. This paper shows that an overview of revolutionary developments in ECDM processes Nomenclature Vc Vapour and gas generation rate Jc Current density R1c-R3c Critical Values Ac Surface area Smrr Specific material removal rate C Total amount of Coulomb on meter Da Average die diameter Dsf Die-shaping factor Q Total amount of power L Vertical height d2 & d3 Conical shape of cylinder section level I & II MRR Material Removal Rate TWR Tool Wear Rate Ra Surface roughness Puf Power Utilisation Factor * Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 . E-mail address: [email protected]
2214-7853 © 2015 Published by Elsevier Ltd. Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing and Characterization. doi:10.1016/j.matpr.2015.07.113
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2. Novel ECDM Theoretical Model IndrajitBasak et al [2] has developed a theoretical model for identifying current and voltage for calculating discharge produced in between electrodes & electrolytes shown in Eq.(1) A. B. E. Khairy et al [3] has employed to producing small shallow dies. The output responses are found out MRR, surface integrity, dimensional quality. In this analyzing experimental & theoretical model for that taking data of MRR, power utilization factor & die-shaping factor. The experimenter was done on 316Stainless Steel Alloy material Eq. (2,3,4) K.L. Bhondwe et al [13] has explored FEM based thermal model for the calculation of material removal rate & which shows that similar accuracy with the experimental results. Rajesh Kumar Porwal et al [21] have made finite element method (FEM) model adapted to the thermal effect during the machining process and artificial neural network (ANN) model used to analyse MRR and ASR for different input conditions. Chenjun Wei et al [27] have generated a finite element model drilling in less than 300μm deep machining in the hydrodynamic regime. The developed model results match with the experimental results.
vc
JcAc[ R1c R 2 c R 3c ]
smrr 23.55 u da / c puf smrr u c / q dsf (d 2 d 3) / L
(1)
2
(2) (3) (4)
Grzegorz Skrabalak et al [34] have produced fuzzy-logic control system for enhancing micro-cracks. MRR and surface roughness parameter & also made a model of the current in electrochemical dissolution and electro discharge machining process. T.K.K.R. Mediliyegedara et al [35] has advised voltage, current waveforms and pulse parameters by using feed-forward neural network and their activation functions. Baoyang Jiang et al [37] The tapered tool electrodes were made to boost the consistency of spark generation & FEM model was investigated to correlate spark energy and the geometry of removed material. J. A. McGeough et al [43] has some effects of the pulsed voltage and vibrating tool-electrode waveforms are subjected to theoretical analysis the effect of the phaseangle between the voltage and vibration waveforms on metal machining rates is also of the view. These results compare with experimental results, and the influence of electrical discharges in the electrolyte is shown to become the major factor promoting enhanced rates of metal removal. V.K. Jain et al [44]. Has proposed electrochemical discharge is modelled associated with the arc discharge valves. The spark energy and the approximate order of hydrogen gas bubble diameter are produced by the proposed valve theory. Estimated material removal rate, overcut and maximum penetration depth show a better conformity with experimental 3. Novel ECDM Process Design B. R. Sarkar et al [14] has carried out experiments on silicon nitride ceramic material to machined & results were found out that machining effect as the voltage has a more significant factor on Material Removal Rate, Radial Overcut, and Heat Affected Zone. B. Doloi et al [15] has carried out the drilling was done on zirconium oxide ceramic work piece material. The applied voltage, electrolyte concentration and inter electrode gap are the three important parameters which significantly influence the MRR as well as the ROC of ECDM process. V. Raghuram et al [1] has determined a separate circuit with respect to current & voltage and electrolytes for experimenting on drill in quartz & studying internal behaviour process of inductance & capacitance in electrolytes. J.W.Liu et al [6] has conducted experimented with particulate reinforced metal matrix composite material is machined by using ECDM process. Developing new technique that is applying the electric field acting on a hydrogen bubble in ECDM processes. Cheng-Kuang Yang et al [7] has developed two processes firstly the typical type’s tool electrode produced by utilizing wire electrical discharge grinding then this tool was used for machining. Surface roughness of the electrode affects wettability tool during machining of work-piece.
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Cheng-Kuang Yang et al [8] have attempted drilling a through hole in hard and brittle materials for that purpose they produced tool electrode with a spherical end whose diameter is greater than that of its cylindrical body. The workpiece was regarded as quartz. The results obtained as a result using this are increasing machining performance and shape accuracy of the micro through hole. Compare to conventional cylindrical tool electrode this tool gives better results Kuan-Yuan Kuo et al [9] have proposed wire electrochemical discharge machining (WECDM) process used to machine quartz glass with electrolyte supplied in titrated flow. The results obtained were satisfactory machining performance, superior surface quality, cost effective & pollution free. Mohammad Reza Razfar et al [11] has demonstrated longitudinal oscillation applied to the cathode electrode during the electrochemical discharge micro drilling of glass and the effects of electrolyte flushing alteration in both discharge and hydrodynamic regimes in the process has been found out. In this experimentation longitudinal waveform including square and sinusoidal were applied to the tool & comparing their output results. Leszek Kudla [17] have carried out micro-holes in borosilicate glass & partly in diamond crystals by using ECDM & producing micro hole by using various shapes of electrode tip and comparing their results. Lijo Paul and Somashekhar S. Hiremath [18] have experimented on borosilicate glass to obtain a blind hole. The Experimental & process parameters are optimized using Taguchi Method & Response surface modelling for output parameters of MRR & TWR. Debasish Nandi et al [22] have studied the behavior of bubbles developed around the electrodes factors affecting bubbles formed for that is voltage-current with this factor analyzed combinations of the electrolytes, tool diameter and tool depth. So, it found out that the local turbulence produced during the process has little effect on critical voltage or critical current Sumit K. Jui et al [12] has made the high aspect ratio micro tools, fabricated in-house used in deep micro-hole drilling on glass using low electrolyte concentration. An aspect ratio of 11 has been achieved & surface roughness less than 100μm were promoted on glass. Jana D. AbouZiki et al [31] has presented Spark assisted chemical engraving (SACE) technology for micro-texturing of glass micro-channel surfaces. The electrolyte viscosity was the most significant factor affecting the channel texture other than tool-work piece gap, machining voltage, and tool travels speed parameters. SACE technology is beneficial for channel microTexturing in micro-fluidic and biomedical applications. Naveen Gautam& Vijay K. Jain [32] in this experimented on borosilicate glass & quartz using the rotational tool with controlled feed gives improved the process performance. Finding out surface integrity, maximum machined depth & MRR. Y.S. Laio et al [16] have added Sodium Dodecyl Sulfate (SDS) surfactant into electrolyte for machining of quartz. Results were found that, a less taper and a better quality, but a little over size hole can be drilled with a higher engraving speed when the current density is raised. Sanjay K. Chak&P. Venkateswara Rao [19] has established machined such as aluminum oxide (Al2O3).The author discovered the drilling of deep holes in ceramics is possible by using pulsed DC associated with abrasive rotary electrode. Due to this the overall improvement in the quality of holes obtained. Alakes Manna &Vivek Narang [20] The e-glass–fiber–epoxy composite machined using novel designed a square cross section with centrally micro hole brass tool and different diameter round-shaped micro tools made of IS-3748 steel. For the making of a special contour shape on this material is possible. J. W. Liu et al [23] has compared GECDM to ECDM process for machining particulate reinforced metal matrix composites. Using GECDM higher machining efficiency and a better surface quality than that of ECDM Chih-Ping Cheng et al [24] has suggested the magneto hydro dynamic convection effect improves electrolyte circulation used in ECDM process in order to improve the machining accuracy and efficiency. Micro-holes in glass with a depth of 450μm are drilled in less than 20s is achieved. Yasuhiro Mochimaru et al [25] have investigated a feedback circuit to stop machining process. It is two step machining process. The circuit detects the electrical current and stop machining immediately after penetrated on. Micro hole obtained up to 12μm. Dae-Jin Kim et al [28] has found out the solution when heat affecting zones (HAZ) occurs during micro drilled. The experiment was performed in the Pyrex glass using rectangular voltage pulses it reduces HAZ & analysis of input parameters such as voltage pulse frequency and duty ratio & getting the results of MRR & micro-drilled surface quality. C.T. Yang et al [29] has obtained better over cut quality by adding SiC abrasive to the electrolyte. It is an association process of discharge, chemical etching and abrasive cutting. Finally studied the consequences occur, such as effects on expansion, surface roughness and material removal rate. Min-Seop Han et al [36] has conducted experiments by using fine graphite powder mixed with the electrolyte has been included in the ECDM process. The workpiece material was seen as borosilicate glass. Owing to this process surface quality was improved
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compared to the conventional process. Baoyang Jiang et al [37] have reported that tapered tool electrodes were produced to enhance the consistency of spark generation. A finite element based model was designed to correlate spark energy and the geometry of removing material. Predictions of material removal from the model demonstrated good consistent with experimental results. Min-Seop Han et al [40] has a cylindrical tool with micro-textures on the surface is suggested as a cutting electrode of soda-lime glass using the proposed method is necessary to demonstrate. In this study, a new type of micro-ECDM cutting tool was proposed, utilizing surface texturing of the tool electrode. The tool surface textures were produced by the EDM process. Improved surface integrity via the proposed method was experimentally verified by cutting soda-lime glass with a thickness of 0.4mm. The smallest Ra, among the machined surfaces was 0.3mm. M. R. Dhanvijay& B. B. Ahuja [42] has demonstrated tool mechanisms and machining of ceramics using stagnant and electrolyte flow method using copper and stainless steel tool by varying the voltage, electrolyte concentration, duty factor and pulse on time. Proposed work shows that continuous flow of electrolyte with stainless steel tool gives the highest MRR, but at the same time a high diametric overcut which has to be minimized. Zhi-Ping Zheng et al [45] have demonstrated a pulse voltage configuration is induced to improve the spark stability so as to increase the machining reproducibility. The results suggest that optimum combinations of both pulse voltage and electrode rotational rate can realize a better machining accuracy. Finally, the complex 3D microstructures are made to demonstrate the great potential of ECDM process 4. Novel ECDM Machine Design M. Schopf et al [4] has developed ECDM used to trueing & dressing of metal bonded diamond tools and this is used further for grinding of hard material like cermets, ceramics. Using this process achieved Ra value of 0.263μm taking work-piece material is Cermet TCM 10. The researcher found that the better surface quality and roundness compare to conventional mechanical trueing and dressing methods. Xuan Doan Cao et al [5] have produced the 3D microstructures producing glass by using machining process of drilling & milling. Author achieved by using ECDM process Ø60μm micro-holes & 3D microstructure such as micro-grooves, micro-pillar, micro-wall, and micropyramid. T.K.K.R. Mediliyegedara et al [10] has investigated innovative design of personal computer based real time controller for the ECDM process for that a process control algorithm was developed in software form. Using this design author found out the results are the metal removal rate and surface finish was increased. M. Coteata et al [26] has fabricated crank mechanism which is attached to the ECDM process in that the material removal rate depends on the rotation of the electrode-tool with the help of a crank mechanism. Chenjun Wei et al [30] A novel electrochemical discharge dressing (ECDD) is developed. The grinding bit is an auxiliary electrode connected to the cathode and anode to the power supply. Cathode is plunged into an electrolyte. The dressing eliminates the electrochemical discharge effect. Choosing this surface morphology of the tool, grinding force and surface roughness of the work-piece are identified. W.Y. Peng et al [33] The novel method developed travelling wire electrochemical discharge machining to slice the optical glass and quartz bars. The electrical–thermal etching effect and its feasibility are considered. The ion translation rate, the electrolyte immersing depth and the concentration of the alkali is established to be the dominant factors of bubbles reaction. The results obtained with respect to reactive wire length, electrolyte supply, power source modulation, effects of the voltage, frequency and duty factor & types of materials. B. Bhattacharyya et al [38] In this using a modular mechatronic feature designed and developed machining setup for carrying out experimental investigations. Such experimental investigations, on the material removal rate and over-cut phenomena in the ECDM process, the machining of aluminium oxide ceramic a pulsed d.c. electricity supply had been applied to the drilling operation of ceramic work-samples. Parametric combinations for enhancing the machining rate and accuracy. V. Fascio et al [39] the spark assisted chemical engraving (SACE) of glass current/voltage measurements combined with photographs of the tool electrode under different regimes. Author presented current/voltage measurements as a new technique to explore SACE. Lijo Paul & Somashekhar S Hiremath [41] has made a prototype model of ECDM was developed with micro linear actuators & A XY scanning device to machine micro hole in silicon wafer using stainless steel wire. Characterization of micro holes material removal rate, radius of overcut & heat affected zone. Sanjay K. Chak & P. Venkateswara Rao [46] the trepanning method was used to eliminate micro cracks when drilling is occurring. Trepanning operation on Al 2O3 a spring fed cylindrical abrasive electrode of 1.5mm diameters has been employed with input parameters of pulsed DC supply voltage, duty
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factor and electrolyte conductivity & their levels. By utilizing this, it enhances the machining performance. Margareta Coteata et al [47] In this new process was developed spring used for transferring semidielectric-type work liquids to workpiece. It gives motion for the gradual penetration of the electrode tool in the workpiece material of steel 5. Analysis of ECDM process parameters In this studied all available literature resources data using this segregate into various parameters which is used by researchers. The analysis was done on the basis of electrolyte, work-piece & Tool material parameters used in ECDM as follows Electrolyte NaOH-[1-2][5][11-14][17][18][20-22][25][27][29-33][36-42][47],KOH-[1-2] [5] [15] [16][24] [28] [29] [33] [45] , Mixed NaOH & KOH-[19][46], De-ionized water& KOH-[7-9],HCL-[1][22],NaCl-[2][22] Kcl[1],NaClO3 [3],NaNo3 [6][35][43],SDS added KOH-[1],KNO3[17],H2SO4[17],(Na2O.nSiO2)-[47] Work-piece Pyrex-[1] [24][28][29][45],Glass-[2][12][22][39],316 Stainless Steel-[3],Cermet-[4],Soda lime glass-[5][11] [13] [27][31][37][40],MMC-[6],Quartz-[7-9][16][32][33],Al2O3-[13][19][23][30] [38][42][46],Silicon Nitride[14][21],Zirconium oxide-[15],Borosilicate glass-[17][18][25][32] [33][36],Diamond Crystals-[17],e-glass–fibre– epoxy composite-[20],Mild Steel- [35][43],Silicon Wafer-[41],Steel –[47]
Fig.1. a) Percentage of work-piece used b) Percentage of electrolyte used
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Table1. Electrode tools used in ECDM Ref No. 1 5 6 8 9 11 12 14 18 20 21 22 24 25 27 28
Cathode Thoriated tungsten Tungsten carbide Steel Tungsten carbide CuZn73 brass wire Tungsten carbide 304 L Tungsten carbide Stainless steel Tungsten carbide IS-3748/T35Cr5Mo1V30 Stainless steel tool Carbon rod Tungsten carbide Tungsten Tungsten carbide Pt plate
Anode Graphite Platinum MMC Graphite Graphite Stainless steel Tool steel block Stainless steel Graphite Copper Stainless steel Carbon rod Graphite Graphite Graphite Cu & Graphite
6. Conclusion Many researchers come forward for research in the field of micromachining in that ECDM machining process are one of the field of micromachining in non-conducting materials specially for hard & brittle materials glass, ceramics &composite materials still this area is only for research work. This machining process not yet used in industrial application due to complexity in the process. The review reveals that researchers are developed EDCM on the basis of a theoretical model, novel ECDM process design, Novel ECDM machine design. Analysis of all review paper shows that most of the researchers used NaOH electrolyte. In case of tool material Tungsten carbide (cathode) & Graphite (Anode) is used and for work-piece material researcher used a variety of non-conducting material such as glass & ceramics Acknowledgements The author gratefully acknowledges the help provided for guiding this research paper by Dr. Raj Ballav& Dr. Amaresh Kumar, Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur References [1] V. Raghuram et al, Effect of the circuit parameters on the electrolytes in the electrochemical discharge phenomenon, Journal of Materials Processing Technology 52 (1995) pp. 301-318 [2] IndrajitBasak&Amitabha Ghosh, Mechanism of spark generation during electrochemical discharge machining : a theoretical model and experimental verification, Journal of Materials Processing Technology 62 (1996) pp. 46-53 [3] A. B. E. Khairy& J. A. McGeough, Die-Sin king by Electroerosion-Dissolution Machining,Annals of the ClRP Vol. 39 (1990) pp.191-195 [4] M. Schopf et al, ECDM (Electro Chemical Discharge Machining), a New Method for Trueing and Dressing of Metal Bonded Diamond Grinding Tools, CIRP Annals - Manufacturing Technology, Volume 50, Issue 1,(2001), pp. 125-128 [5] Xuan Doan Cao et al, Micro-structuring of glass with features less than 100μm by electrochemical discharge machining, Precision Engineering 33 (2009) pp.459–465 [6] J.W.Liu et al, An analysis of the discharge mechanism in electrochemical discharge machining of particulate reinforced metal matrix composites, Int. Journal of Machine Tools &Manf. 50 (2010) 86–96 [7] Cheng-Kuang Yang et al, Effect of surface roughness of tool electrode materials in ECDM performance, International Journal of Machine Tools & Manufacture 50 (2010) pp.1088–1096
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[8] Cheng-Kuang Yang et al, Enhancement of ECDM efficiency and accuracy by spherical tool electrode, International Journal of Machine Tools & Manufacture 51 (2011) pp.528–535 [9] Kuan-Yuan Kuo et al, Wire electrochemical discharge machining (WECDM) of quartz glass with titrated electrolyte flow, International Journal of Machine Tools & Manufacture72 (2013) pp.50–57 [10] T.K.K.R. Mediliyegedara et al, New developments in the process control of the hybrid electro chemical discharge machining (ECDM) process, Journal of Matl Processing Tech 167 (2005) 338–343 [11] Mohammad Reza Razfar et al, Study of the effects of tool longitudinal oscillation on the machining speed of electrochemical discharge drilling of glass, Precision Engineering 38 (2014) pp.885–892 [12] Sumit K. Jui et al, High aspect ratio micromachining of glass by electrochemical discharge machining (ECDM), Journal of Manufacturing Processes 15 (2013) pp.460–466 [13] K.L. Bhondwe et al, Finite element prediction of material removal rate due to electro-chemical sparks machining International Journal of Machine Tools & Manufacture 46 (2006) pp.1699–1706 [14] B. R. Sarkar et al, Parametric analysis on electrochemical discharge machining on silicon nitride” Intenational, Journal of Advanced Manufacturing Technology 28 (2006) pp.873-881 [15] B. Doloi et al, Electrochemical Discharge Machining of Non-Conducting Ceramics, Defence Science Journal, Vol 49, No 4, August 1999, pp.331-338 [16] Y.S. Laio et al, A study to improve drilling quality of electrochemical discharge machining (ECDM) process, Procedia CIRP 6 (2013) pp.609 – 614 [17]LeszekKudla, Investigation into electrochemical discharge machining of microholes, Journal of Automation Mobile Robotics & Intelligent Systems Vol 3, No 4 (2009) pp. 21-24 [18] Lijo Paul and Somashekhar S. Hiremath Response, Surface Modelling of Micro Holes in Electrochemical Discharge Machining Process, Procedia Engineering 64 (2013) pp.1395 – 1404 [19] Sanjay K. Chak&P. Venkateswara Rao, The drilling of Al2O3 using a pulsed DC supply with a rotary abrasive electrode by the electrochemical discharge process, International Journal of Advanced Manufacturing Technology 39(2008) pp.633–641 [20] Alakesh Manna &VivekNarang, A study on micro machining of e-glass–fibre–epoxy composite by ECSM process, International Journal of Advanced Manufacturing Technology 61 (2012) pp.1191–1197 [21]Rajesh Kumar Porwal et al, Modelling and multi-response optimization of hole sinking electrical discharge micromachining of titanium alloy thin sheet, Journal of Mechanical Science and Technology 28 (2) (2014) pp.653-661 [22] Debasish Nandi et al, Behaviour of bubbles generated in electrochemical discharge machining, International Journal of Engineering Science and TechnologyVol. 3 No.12 December 2011 pp.8274-8280 [23] J. W. Liu et al, Grinding-aided electrochemical discharge machining of particulate reinforced metal matrix composites, International Journal of Advanced Manufacturing Technology 68(2013) 2349–2357 [24]Chih-Ping Cheng et al, Magnetic field-assisted electrochemical discharge machining, Journal of Micromechanics and Microengineering20 (2010) pp. 1-7 [25] Yasuhiro Mochimaru et al, Micro Hole Processing Using Electro-Chemical Discharge Machining, Journal of Advanced Mechanical Design Systems and Manufacturing Vol. 6, No. 6, (2012) pp. 949-957 [26] M. Coteata et al, Establishing the electrical discharges weight in electrochemical discharge drilling, International Journal of Material Forming Vol. 2 Suppl 1 (2009) pp.673–676 [27]Chenjun Wei et al, A finite element based model for electrochemical discharge machining in discharge regime, International Journal of Advanced Manufacturing Technology 54 (2011) pp.987–995 [28]Dae-Jin Kim et al, Voltage pulse frequency and duty ratio effects in an electrochemical discharge micro drilling process of Pyrex glass, International Journal of Machine Tools & Manufacture 46 (2006) pp. 1064–1067 [29] C.T. Yang et al, Huang Improving machining performance of wire electrochemical discharge machining by adding SiC abrasive to electrolyte, Intl Journal of Machine Tools & Manufacture 46 (2006) 2044–2050 [30] Chenjun Wei et al, Electrochemical discharge dressing of metal bond micro-grinding tools, International Journal of Machine Tools & Manufacture 51 (2011) pp.165–168 [31] Jana D.AbouZiki et al, Micro-texturing channel surfaces on glass with spark assisted chemical engraving, International Journal of Machine Tools & Manufacture 57 (2012) pp.66–72 [32] Naveen Gautam& Vijay K. Jain, Experimental investigations into ECSD process using various tool kinematics, International Journal of Machine Tools & Manufacture Vol 38, No. 1-2, (1998) pp. 15-27 [33] W.Y. Peng et al, Study of electrochemical discharge machining technology for slicing non-conductive brittle materials, Journal of Materials Processing Technology 149 (2004) pp.363–369 [34]GrzegorzSkrabalak et al, Building of rules base for fuzzy-logic control of the ECDM process, Journal of Materials Processing Technology 149 (2004) pp.530–535 [35] T.K.K.R. Mediliyegedara et al, An intelligent pulse classification system for electro-chemical discharge machining (ECDM)—a preliminary study, Journal of Matl Processing Tech 149 (2004) 499–503 [36] Min-Seop Han et al Improvement of surface integrity of electro-chemical discharge machining process using powder-mixed electrolyte, Journal of Matls Processing Technology 191 (2007) 224–227 [37] Baoyang Jiang et al,Experimental investigation of spark generation in electrochemical discharge machining of non-conducting material, Journal of Materials Processing Technology 214 (2014) 892– 898 [38] B. Bhattacharyya et al, Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials, Journal of Matls Processing Technology 95 (1999) 145-154 [39] V. Fascio et al, Investigations of the spark assisted chemical engraving, Electrochemistry Communications 5 (2003) pp.203–207 [40] Min-Seop Han et al, Micro-electrochemical discharge cutting of glass using a surface-textured tool, CIRP Journal of Manufacturing Science and Technology 4 (2011) pp.362–369 [41]Lijo Paul &Somashekhar S Hiremath, Evaluation of process parameters of ECDM using Grey Relational Analysis, Procedia Materials
Pravin Pawar et al. / Materials Today: Proceedings 2 (2015) 3188 – 3195 Science 5 (2014 ) pp.2273 – 2282 [42] M. R. Dhanvijay& B. B. Ahuja, Micromachining of ceramics by Electrochemical Discharge process considering stagnant and electrolyte flow method, Procedia Technology 14 ( 2014 ) pp.165 – 172 [43] J. A. McGeough et al, Theoretical and Experimental Investigation of the Relative Effects of Spark Erosion and Electrochemical Dissolution in Electrochemical ARC Machining, Annals of the CIRP Vol. 32 (1983) pp. 113-118 [44] V.K. Jain et al, On the analysis of the electrochemical spark machining process, International Journal of Machine Tools & Manufacture 39 (1999) pp.165–186 [45] Zhi-Ping Zheng et al, Feasibility of 3D Surface Machining on Pyrex Glass by Electrochemical Discharge Machining (ECDM), Proc. AEMS07, Nagoya Japan; 28-30 Nov., (2007) pp. 98-103 [46] Sanjay K. Chak et al, Trepanning of Al2O3 by electro-chemical discharge machining (ECDM) process using abrasive electrode with a pulsed DC supply, International Journal of Machine Tools & Manufacture 47 (2007) pp. 2061–2070 [47] Margareta Coteaţa et al, Drilling of Difficult-to-Cut Steel by Electrochemical Discharge Machining, Materials and Manufacturing Processes, 26(2011) pp.1466–1472 [48] Dinesh Kumar Koli et al, A Review on Properties, Behaviour and Processing Methods for Al- Nano Al2O3 Composites, Procedia Materials Science 6 ( 2014 ) 567 – 589
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ScienceDirect Materials Today: Proceedings 2 (2015) 3188 – 3195
4th International Conference on Materials Processing and Characterization
Revolutionary Developments in ECDM Process: An Overview PravinPawara*, Raj Ballavb, Amaresh Kumarc a
Ph.D Research Scholar , Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur,831014,India b,c Associate Professor, Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur,831014,India
Abstract This paper shows a review on ECDM process on the basis of Novel theoretical model, novel process, and novel machine design © 2014Published The Authors. Elsevier © 2015 by Elsevier Ltd.Ltd. All rights reserved. Selection andpeer-review peer-review under responsibility ofconference the conference committee members ofInternational the 4th International on Selection and under responsibility of the committee members of the 4th conferenceconference on Materials ProcessingProcessing and Characterization. Materials and Characterization. Keywords: Electro chemical discharge machining
1. Introduction Electro chemical discharge machining (ECDM) is a hybrid non-conventional manufacturing process which combines the features of electro chemical machining (ECM) and electro discharge machining (EDM) [3][4][10][11] [13]. This paper shows that an overview of revolutionary developments in ECDM processes Nomenclature Vc Vapour and gas generation rate Jc Current density R1c-R3c Critical Values Ac Surface area Smrr Specific material removal rate C Total amount of Coulomb on meter Da Average die diameter Dsf Die-shaping factor Q Total amount of power L Vertical height d2 & d3 Conical shape of cylinder section level I & II MRR Material Removal Rate TWR Tool Wear Rate Ra Surface roughness Puf Power Utilisation Factor * Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 . E-mail address: [email protected]
2214-7853 © 2015 Published by Elsevier Ltd. Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing and Characterization. doi:10.1016/j.matpr.2015.07.113
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2. Novel ECDM Theoretical Model IndrajitBasak et al [2] has developed a theoretical model for identifying current and voltage for calculating discharge produced in between electrodes & electrolytes shown in Eq.(1) A. B. E. Khairy et al [3] has employed to producing small shallow dies. The output responses are found out MRR, surface integrity, dimensional quality. In this analyzing experimental & theoretical model for that taking data of MRR, power utilization factor & die-shaping factor. The experimenter was done on 316Stainless Steel Alloy material Eq. (2,3,4) K.L. Bhondwe et al [13] has explored FEM based thermal model for the calculation of material removal rate & which shows that similar accuracy with the experimental results. Rajesh Kumar Porwal et al [21] have made finite element method (FEM) model adapted to the thermal effect during the machining process and artificial neural network (ANN) model used to analyse MRR and ASR for different input conditions. Chenjun Wei et al [27] have generated a finite element model drilling in less than 300μm deep machining in the hydrodynamic regime. The developed model results match with the experimental results.
vc
JcAc[ R1c R 2 c R 3c ]
smrr 23.55 u da / c puf smrr u c / q dsf (d 2 d 3) / L
(1)
2
(2) (3) (4)
Grzegorz Skrabalak et al [34] have produced fuzzy-logic control system for enhancing micro-cracks. MRR and surface roughness parameter & also made a model of the current in electrochemical dissolution and electro discharge machining process. T.K.K.R. Mediliyegedara et al [35] has advised voltage, current waveforms and pulse parameters by using feed-forward neural network and their activation functions. Baoyang Jiang et al [37] The tapered tool electrodes were made to boost the consistency of spark generation & FEM model was investigated to correlate spark energy and the geometry of removed material. J. A. McGeough et al [43] has some effects of the pulsed voltage and vibrating tool-electrode waveforms are subjected to theoretical analysis the effect of the phaseangle between the voltage and vibration waveforms on metal machining rates is also of the view. These results compare with experimental results, and the influence of electrical discharges in the electrolyte is shown to become the major factor promoting enhanced rates of metal removal. V.K. Jain et al [44]. Has proposed electrochemical discharge is modelled associated with the arc discharge valves. The spark energy and the approximate order of hydrogen gas bubble diameter are produced by the proposed valve theory. Estimated material removal rate, overcut and maximum penetration depth show a better conformity with experimental 3. Novel ECDM Process Design B. R. Sarkar et al [14] has carried out experiments on silicon nitride ceramic material to machined & results were found out that machining effect as the voltage has a more significant factor on Material Removal Rate, Radial Overcut, and Heat Affected Zone. B. Doloi et al [15] has carried out the drilling was done on zirconium oxide ceramic work piece material. The applied voltage, electrolyte concentration and inter electrode gap are the three important parameters which significantly influence the MRR as well as the ROC of ECDM process. V. Raghuram et al [1] has determined a separate circuit with respect to current & voltage and electrolytes for experimenting on drill in quartz & studying internal behaviour process of inductance & capacitance in electrolytes. J.W.Liu et al [6] has conducted experimented with particulate reinforced metal matrix composite material is machined by using ECDM process. Developing new technique that is applying the electric field acting on a hydrogen bubble in ECDM processes. Cheng-Kuang Yang et al [7] has developed two processes firstly the typical type’s tool electrode produced by utilizing wire electrical discharge grinding then this tool was used for machining. Surface roughness of the electrode affects wettability tool during machining of work-piece.
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Cheng-Kuang Yang et al [8] have attempted drilling a through hole in hard and brittle materials for that purpose they produced tool electrode with a spherical end whose diameter is greater than that of its cylindrical body. The workpiece was regarded as quartz. The results obtained as a result using this are increasing machining performance and shape accuracy of the micro through hole. Compare to conventional cylindrical tool electrode this tool gives better results Kuan-Yuan Kuo et al [9] have proposed wire electrochemical discharge machining (WECDM) process used to machine quartz glass with electrolyte supplied in titrated flow. The results obtained were satisfactory machining performance, superior surface quality, cost effective & pollution free. Mohammad Reza Razfar et al [11] has demonstrated longitudinal oscillation applied to the cathode electrode during the electrochemical discharge micro drilling of glass and the effects of electrolyte flushing alteration in both discharge and hydrodynamic regimes in the process has been found out. In this experimentation longitudinal waveform including square and sinusoidal were applied to the tool & comparing their output results. Leszek Kudla [17] have carried out micro-holes in borosilicate glass & partly in diamond crystals by using ECDM & producing micro hole by using various shapes of electrode tip and comparing their results. Lijo Paul and Somashekhar S. Hiremath [18] have experimented on borosilicate glass to obtain a blind hole. The Experimental & process parameters are optimized using Taguchi Method & Response surface modelling for output parameters of MRR & TWR. Debasish Nandi et al [22] have studied the behavior of bubbles developed around the electrodes factors affecting bubbles formed for that is voltage-current with this factor analyzed combinations of the electrolytes, tool diameter and tool depth. So, it found out that the local turbulence produced during the process has little effect on critical voltage or critical current Sumit K. Jui et al [12] has made the high aspect ratio micro tools, fabricated in-house used in deep micro-hole drilling on glass using low electrolyte concentration. An aspect ratio of 11 has been achieved & surface roughness less than 100μm were promoted on glass. Jana D. AbouZiki et al [31] has presented Spark assisted chemical engraving (SACE) technology for micro-texturing of glass micro-channel surfaces. The electrolyte viscosity was the most significant factor affecting the channel texture other than tool-work piece gap, machining voltage, and tool travels speed parameters. SACE technology is beneficial for channel microTexturing in micro-fluidic and biomedical applications. Naveen Gautam& Vijay K. Jain [32] in this experimented on borosilicate glass & quartz using the rotational tool with controlled feed gives improved the process performance. Finding out surface integrity, maximum machined depth & MRR. Y.S. Laio et al [16] have added Sodium Dodecyl Sulfate (SDS) surfactant into electrolyte for machining of quartz. Results were found that, a less taper and a better quality, but a little over size hole can be drilled with a higher engraving speed when the current density is raised. Sanjay K. Chak&P. Venkateswara Rao [19] has established machined such as aluminum oxide (Al2O3).The author discovered the drilling of deep holes in ceramics is possible by using pulsed DC associated with abrasive rotary electrode. Due to this the overall improvement in the quality of holes obtained. Alakes Manna &Vivek Narang [20] The e-glass–fiber–epoxy composite machined using novel designed a square cross section with centrally micro hole brass tool and different diameter round-shaped micro tools made of IS-3748 steel. For the making of a special contour shape on this material is possible. J. W. Liu et al [23] has compared GECDM to ECDM process for machining particulate reinforced metal matrix composites. Using GECDM higher machining efficiency and a better surface quality than that of ECDM Chih-Ping Cheng et al [24] has suggested the magneto hydro dynamic convection effect improves electrolyte circulation used in ECDM process in order to improve the machining accuracy and efficiency. Micro-holes in glass with a depth of 450μm are drilled in less than 20s is achieved. Yasuhiro Mochimaru et al [25] have investigated a feedback circuit to stop machining process. It is two step machining process. The circuit detects the electrical current and stop machining immediately after penetrated on. Micro hole obtained up to 12μm. Dae-Jin Kim et al [28] has found out the solution when heat affecting zones (HAZ) occurs during micro drilled. The experiment was performed in the Pyrex glass using rectangular voltage pulses it reduces HAZ & analysis of input parameters such as voltage pulse frequency and duty ratio & getting the results of MRR & micro-drilled surface quality. C.T. Yang et al [29] has obtained better over cut quality by adding SiC abrasive to the electrolyte. It is an association process of discharge, chemical etching and abrasive cutting. Finally studied the consequences occur, such as effects on expansion, surface roughness and material removal rate. Min-Seop Han et al [36] has conducted experiments by using fine graphite powder mixed with the electrolyte has been included in the ECDM process. The workpiece material was seen as borosilicate glass. Owing to this process surface quality was improved
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compared to the conventional process. Baoyang Jiang et al [37] have reported that tapered tool electrodes were produced to enhance the consistency of spark generation. A finite element based model was designed to correlate spark energy and the geometry of removing material. Predictions of material removal from the model demonstrated good consistent with experimental results. Min-Seop Han et al [40] has a cylindrical tool with micro-textures on the surface is suggested as a cutting electrode of soda-lime glass using the proposed method is necessary to demonstrate. In this study, a new type of micro-ECDM cutting tool was proposed, utilizing surface texturing of the tool electrode. The tool surface textures were produced by the EDM process. Improved surface integrity via the proposed method was experimentally verified by cutting soda-lime glass with a thickness of 0.4mm. The smallest Ra, among the machined surfaces was 0.3mm. M. R. Dhanvijay& B. B. Ahuja [42] has demonstrated tool mechanisms and machining of ceramics using stagnant and electrolyte flow method using copper and stainless steel tool by varying the voltage, electrolyte concentration, duty factor and pulse on time. Proposed work shows that continuous flow of electrolyte with stainless steel tool gives the highest MRR, but at the same time a high diametric overcut which has to be minimized. Zhi-Ping Zheng et al [45] have demonstrated a pulse voltage configuration is induced to improve the spark stability so as to increase the machining reproducibility. The results suggest that optimum combinations of both pulse voltage and electrode rotational rate can realize a better machining accuracy. Finally, the complex 3D microstructures are made to demonstrate the great potential of ECDM process 4. Novel ECDM Machine Design M. Schopf et al [4] has developed ECDM used to trueing & dressing of metal bonded diamond tools and this is used further for grinding of hard material like cermets, ceramics. Using this process achieved Ra value of 0.263μm taking work-piece material is Cermet TCM 10. The researcher found that the better surface quality and roundness compare to conventional mechanical trueing and dressing methods. Xuan Doan Cao et al [5] have produced the 3D microstructures producing glass by using machining process of drilling & milling. Author achieved by using ECDM process Ø60μm micro-holes & 3D microstructure such as micro-grooves, micro-pillar, micro-wall, and micropyramid. T.K.K.R. Mediliyegedara et al [10] has investigated innovative design of personal computer based real time controller for the ECDM process for that a process control algorithm was developed in software form. Using this design author found out the results are the metal removal rate and surface finish was increased. M. Coteata et al [26] has fabricated crank mechanism which is attached to the ECDM process in that the material removal rate depends on the rotation of the electrode-tool with the help of a crank mechanism. Chenjun Wei et al [30] A novel electrochemical discharge dressing (ECDD) is developed. The grinding bit is an auxiliary electrode connected to the cathode and anode to the power supply. Cathode is plunged into an electrolyte. The dressing eliminates the electrochemical discharge effect. Choosing this surface morphology of the tool, grinding force and surface roughness of the work-piece are identified. W.Y. Peng et al [33] The novel method developed travelling wire electrochemical discharge machining to slice the optical glass and quartz bars. The electrical–thermal etching effect and its feasibility are considered. The ion translation rate, the electrolyte immersing depth and the concentration of the alkali is established to be the dominant factors of bubbles reaction. The results obtained with respect to reactive wire length, electrolyte supply, power source modulation, effects of the voltage, frequency and duty factor & types of materials. B. Bhattacharyya et al [38] In this using a modular mechatronic feature designed and developed machining setup for carrying out experimental investigations. Such experimental investigations, on the material removal rate and over-cut phenomena in the ECDM process, the machining of aluminium oxide ceramic a pulsed d.c. electricity supply had been applied to the drilling operation of ceramic work-samples. Parametric combinations for enhancing the machining rate and accuracy. V. Fascio et al [39] the spark assisted chemical engraving (SACE) of glass current/voltage measurements combined with photographs of the tool electrode under different regimes. Author presented current/voltage measurements as a new technique to explore SACE. Lijo Paul & Somashekhar S Hiremath [41] has made a prototype model of ECDM was developed with micro linear actuators & A XY scanning device to machine micro hole in silicon wafer using stainless steel wire. Characterization of micro holes material removal rate, radius of overcut & heat affected zone. Sanjay K. Chak & P. Venkateswara Rao [46] the trepanning method was used to eliminate micro cracks when drilling is occurring. Trepanning operation on Al 2O3 a spring fed cylindrical abrasive electrode of 1.5mm diameters has been employed with input parameters of pulsed DC supply voltage, duty
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factor and electrolyte conductivity & their levels. By utilizing this, it enhances the machining performance. Margareta Coteata et al [47] In this new process was developed spring used for transferring semidielectric-type work liquids to workpiece. It gives motion for the gradual penetration of the electrode tool in the workpiece material of steel 5. Analysis of ECDM process parameters In this studied all available literature resources data using this segregate into various parameters which is used by researchers. The analysis was done on the basis of electrolyte, work-piece & Tool material parameters used in ECDM as follows Electrolyte NaOH-[1-2][5][11-14][17][18][20-22][25][27][29-33][36-42][47],KOH-[1-2] [5] [15] [16][24] [28] [29] [33] [45] , Mixed NaOH & KOH-[19][46], De-ionized water& KOH-[7-9],HCL-[1][22],NaCl-[2][22] Kcl[1],NaClO3 [3],NaNo3 [6][35][43],SDS added KOH-[1],KNO3[17],H2SO4[17],(Na2O.nSiO2)-[47] Work-piece Pyrex-[1] [24][28][29][45],Glass-[2][12][22][39],316 Stainless Steel-[3],Cermet-[4],Soda lime glass-[5][11] [13] [27][31][37][40],MMC-[6],Quartz-[7-9][16][32][33],Al2O3-[13][19][23][30] [38][42][46],Silicon Nitride[14][21],Zirconium oxide-[15],Borosilicate glass-[17][18][25][32] [33][36],Diamond Crystals-[17],e-glass–fibre– epoxy composite-[20],Mild Steel- [35][43],Silicon Wafer-[41],Steel –[47]
Fig.1. a) Percentage of work-piece used b) Percentage of electrolyte used
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Table1. Electrode tools used in ECDM Ref No. 1 5 6 8 9 11 12 14 18 20 21 22 24 25 27 28
Cathode Thoriated tungsten Tungsten carbide Steel Tungsten carbide CuZn73 brass wire Tungsten carbide 304 L Tungsten carbide Stainless steel Tungsten carbide IS-3748/T35Cr5Mo1V30 Stainless steel tool Carbon rod Tungsten carbide Tungsten Tungsten carbide Pt plate
Anode Graphite Platinum MMC Graphite Graphite Stainless steel Tool steel block Stainless steel Graphite Copper Stainless steel Carbon rod Graphite Graphite Graphite Cu & Graphite
6. Conclusion Many researchers come forward for research in the field of micromachining in that ECDM machining process are one of the field of micromachining in non-conducting materials specially for hard & brittle materials glass, ceramics &composite materials still this area is only for research work. This machining process not yet used in industrial application due to complexity in the process. The review reveals that researchers are developed EDCM on the basis of a theoretical model, novel ECDM process design, Novel ECDM machine design. Analysis of all review paper shows that most of the researchers used NaOH electrolyte. In case of tool material Tungsten carbide (cathode) & Graphite (Anode) is used and for work-piece material researcher used a variety of non-conducting material such as glass & ceramics Acknowledgements The author gratefully acknowledges the help provided for guiding this research paper by Dr. Raj Ballav& Dr. Amaresh Kumar, Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur References [1] V. Raghuram et al, Effect of the circuit parameters on the electrolytes in the electrochemical discharge phenomenon, Journal of Materials Processing Technology 52 (1995) pp. 301-318 [2] IndrajitBasak&Amitabha Ghosh, Mechanism of spark generation during electrochemical discharge machining : a theoretical model and experimental verification, Journal of Materials Processing Technology 62 (1996) pp. 46-53 [3] A. B. E. Khairy& J. A. McGeough, Die-Sin king by Electroerosion-Dissolution Machining,Annals of the ClRP Vol. 39 (1990) pp.191-195 [4] M. Schopf et al, ECDM (Electro Chemical Discharge Machining), a New Method for Trueing and Dressing of Metal Bonded Diamond Grinding Tools, CIRP Annals - Manufacturing Technology, Volume 50, Issue 1,(2001), pp. 125-128 [5] Xuan Doan Cao et al, Micro-structuring of glass with features less than 100μm by electrochemical discharge machining, Precision Engineering 33 (2009) pp.459–465 [6] J.W.Liu et al, An analysis of the discharge mechanism in electrochemical discharge machining of particulate reinforced metal matrix composites, Int. Journal of Machine Tools &Manf. 50 (2010) 86–96 [7] Cheng-Kuang Yang et al, Effect of surface roughness of tool electrode materials in ECDM performance, International Journal of Machine Tools & Manufacture 50 (2010) pp.1088–1096
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