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1 5 th International & 26 th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 th 14 th, 2014, IIT Guwahati, Assam, India Parametric Analysis of Electrochemical Discharge Micro-Machining 1 B. Mallick*, 2 M.N. Ali, 3 B. R.Sarkar, 4 B. Doloi, 5 B. Bhattacharyya 1-5 Production Engineering Department, Jadavpur University, Kolkata-32 * bijan.ju@gmail.com mnali.jupe@gmail.com sarkarbiplab_s@rediffmail.com Abstract Electrochemical discharge micro-machining (micro-ecdm) has the ability to machine electrically nonconducting materials as compared with different existing traditional and also non-traditional machining processes. This paper deals with the effects of different process parameters like applied voltage (V), electrolyte concentrations(wt%), pulse frequency and duty ratio on different machining performance characteristics such as material removal rate (MRR), overcut (OC) and heat affected zone (HAZ) during micro-profile generation on electrically non-conducting glass. Applied voltage has been set from V and the electrolyte concentration, pulse frequency and duty factor were varied from 10-30wt%, 200Hz-1kHz and 45-65% respectively during the experimentation. A cylindrical shaped stainless tool of diameter 350 µm and NaOH solution as electrolyte were used to conduct the experiments. Material removal rate is high for 55 V and 30 wt% electrolyte concentration respectively. Overcut and HAZ area decreases with frequency whereas it increases with duty ratio after 50% and 55% of duty ratio respectively. Keywords: µ-ecdm, µ-channel, MRR, OC, HAZ 1. Introduction Electrochemical Discharge micro-machining process is utilized as an advanced hybrid micromachining technique, which is combination of electrochemical machining (ECM) and electro discharge machining (EDM) proposed by Basak et al. (1996). In ECDM process, the material removal takes place due to the combined effects of electrochemical (EC) reaction and electrical spark discharge (ESD) action analyzed by Bhattacharyya et al. (1999), Jain et al. (1999) and Jawalkar et al. (1999). Many researchers have carried out researches to trounce the various drawbacks associated with µ-ecdm process. Cao et al. (2009) studied micro-electrochemical discharge machining to improve the machining of 3D micro-structures on glass and to obtain good surface with minimized structures during drilling and milling operations. Han et al. (2007) reported a new method for improvement of the surface integrity in electrochemical discharge machining (ECDM) process by the use of fine graphite powder mixed with electrolyte. Jui et al. (2013) fabricated in-house high aspect ratio micro-tools, which have been used for deep micro-hole drilling on glass using low electrolyte concentration. An aspect ratio of 11 has been achieved. Kim et al. (2006) studied the voltage pulse frequency and duty ratio effects in an electrochemical discharge micro-drilling process using Pyrex glass materials. Sarkar et al. (2006) showed the effects of various process parameters during micro-drilling of silicon nitride ceramic using electrochemical discharge machining (ECDM) process. Still, a little attention has been drawn in the area of µ-profile or µ-channel cutting on electrically nonconducting materials viz glass and ceramics with ECDM process. Therefore, this paper includes the basic experimental results of profile generation like micro-channel on glass. This paper also deals with the effects of different process parameters like applied voltage (V), electrolyte concentrations(wt%), pulse frequency and duty ratio on different machining performance characteristics such as material removal rate (MRR), overcut (OC) and heat affected zone (HAZ) during micro-channel cutting on electrically non-conducting glass. 2. Experimentation 2.1 Experimental set up To accomplish the objectives of this research work and to control the process parameters such as machining voltage, duty ratio, pulse frequency, electrolyte concentration etc an experimental ECDM 540-1

2 Parametric Analysis of Electrochemical Discharge Micro-Machining set-up was indigenously designed and developed. The set-up includes the following sub systems: a) Mechanical hardware system b) Electrolyte supply System c) Electrical power supply unit The mechanical hardware system is very important parts of micro-ecdm set-up. The mechanical hardware system is used to achieve the goal of the present research work. It consists of the main elements such as (i) Main machining chamber, (ii) Job holding unit, (iii) Tool holding unit, (iv) Auxiliary electrode unit and (v) Job feeding arrangement etc. The main machining chamber is made of Perspex material having rectangular shape. In job holding unit the job is placed on a plate, which itself rests on four springs guided by four stainless steel rod located at four different corners of the plate. The feed to the job is given by spring feed mechanism in the upward direction so that the job can always be in touch with the micro-tool. The tool holding unit is fitted with the cover plate by means of screw-nut mechanism so that the position of the µ-tool can be adjusted according to the requirements to generate the different shapes of the micro-channel. A flat rectangular graphite auxiliary electrode plate is placed parallel to the job holding table. The schematic diagram of main machining chamber of the experimental µ-ecdm setup is shown in Fig. 1. Fig. 1 Schematic diagram of main machining chamber of µ-ecdm set-up 2.2 Experimental Planning To investigate the influences of above process parameters on different machining criteria such as Material Removal Rate (MRR), Heat Affected Zone (HAZ) and Overcut (OC) a cylindrical shaped with flat end stainless tool of diameter 350µm were used for each experiment and the experiments were conducted in a NaOH solution. The process parameters i.e. voltage, electrolyte concentration, pulse frequency and duty ratio have been varied as V; 10-30wt%; Hz and % respectively. Other parameters such as inter-electrode gap and length of tool length have been kept fixed as 50mm and 10mm respectively. Glass slide was chosen as workpiece material to cut µ-channel. During experimentations one parameter has been varied while other process parameters were fixed at low levels within their respective ranges in order to expect minimum effects of these parameters. As the tool material is worn out due to generation of high heat during ECDM process a new identical tool was always used for each experiment. The machining conditions for cutting micro-channel on glass have been shown in Table 1. Machining rate in terms of material removal rate (MRR) has been calculated by weight difference. The width of cut (WOC) and HAZ area of µ-channel were measured using a Leica measuring microscope and overcut was calculated by subtracting the diameter of tool from WOC. Table 1 Machining conditions during µ-channel cutting on glass Expt. No Voltage (V) Elect Conc. (wt %) Pulse Freq. (Hz) Duty Ratio (%) Results and Discussion The data input parameters are applied voltage, electrolyte concentration, pulse frequency and duty ratio and machining characteristics are material removal rate (MRR), overcut (OC) and heat affected zone (HAZ) area. Each experiment was conducted three times at every machining parametric combination. The average values of the experimental results thus obtained were used and plotted in graph to analysis the influences of the various process parameters on various machining characteristics

3 5 th International & 26 th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 th 14 th, 2014, IIT Guwahati, Assam, India Table 2 shows the average values of various machining characteristics recorded during the experimentations. Fig. 3 Effect of electrolyte concentrations on MRR Table 2 Experimental results obtained at different parametric combinations Expt. No MRR (mg/hr) Overcut (µm) HAZ (µm 2 )x Fig. 4 Effects of pulse frequency on MRR Fig. 5 Effects of duty ratio on MRR 3.1 Influences of process parameters on Material Removal Rate (MRR) Fig. 2 Effect of applied voltage on MRR The influences of applied voltage, electrolyte concentration, pulse frequency and duty ratio on average material removal rate for fixed inter-electrode gap when micro-channel is cut on glass using NaOH electrolyte are shown in Fig. 2, 3, 4 and 5 respectively. These figures show that MRR for NaOH electrolyte solution increases with the increase of applied voltage, electrolyte concentration and duty ratio but decreases with increase of pulse frequency. The number of sparking increases with the increase of voltage and electrolyte concentration since the number of sparking increases with the increase of current density and rate of electro-chemical reactions, which increase with increase of voltage and electrolyte concentration respectively. Fig. 2 and 3 reveal that material removal rate is high for 55 V and 30 wt% electrolyte concentration respectively. Also MRR increases with increase of duration of pulse on

4 Parametric Analysis of Electrochemical Discharge Micro-Machining time, which increases with duty factor. As the discharge duration increases, the removal rate increases since the temperature of the glass channel rises. MRR falls down with increase of pulse frequency because the duration of the discharge increases as the frequency decreases, even though the total time that voltage is applied stays the same. 3.2 Influences of process parameters on Overcut (OC) Fig. 6 and 7 exhibit the influences of applied voltage and electrolyte concentration respectively on average overcut using NaOH as electrolyte. Generally, rate of sparking increases with the increase of both applied voltage and electrolyte concentration and consequently increases not only MRR but also width of cut due to side wall sparking from the tool electrode and thereby increases overcut. Fig. 8 and 9 show the variation of overcut with varying pulse frequency and duty ratio respectively. These show that overcut increases with increase of duty ratio and decreases with increase of pulse frequency. One possible reason is that the discharge gets more powerful because the current density on the tool s side surface rises. Photographic views of µ-channel taken using optical microscope at applied voltage 50V and 35V are shown in Fig. 10 and 11 respectively. Fig. 7 Effects of Electrolyte Conc. on Overcut Fig. 8 Effects of Pulse frequency on Overcut Fig. 6 Effects of applied voltage on Overcut Fig. 9 Effects of Duty Ratio on Overcut 540-4

5 5 th International & 26 th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 th 14 th, 2014, IIT Guwahati, Assam, India Fig. 10 µ-channel at 50V/10wt%NaOH/200Hz/45% Fig. 12 Effects of Applied voltage on HAZ area Fig. 11 µ-channel at 35V/10wt%NaOH/200Hz/45% 3.3 Influences of process parameters on Heat Affected Zone (HAZ) area In ECDM process a large amount of heat is generated during the machining of a glass material. A portion of this heat is radiated to atmosphere, some is lost to the electrolyte by convection and remainder is conducted to the workpiece. Fig. 12 and 13 show the influences of applied voltage and electrolyte concentration on average heat affected zone (HAZ) area. From the figures it is clear that that HAZ area almost gradually increases with increase of applied voltage and electrolyte concentration and it becomes higher at 55 V and 30 wt% electrolyte concentration. Variations of HAZ area with pulse frequency and duty ratio are shown in Fig. 14 and 15 respectively. It is obvious from the figures that initially HAZ area increases and then it decreases with frequency whereas it increases with duty ratio after 55% of duty ratio. The discharge heat value is greater for long, slow pulses because the duration of the discharge increases. As a result HAZ grows larger. Fig. 10 and 11 show the photographic views of micro-channels indicating the HAZ area and average HAZ is observed µm 2 and average width of cut (WOC) is found µm. Fig. 13 Effects of Electrolyte Concentrations on HAZ area Fig. 14 Effects of Pulse frequency on HAZ 540-5

6 Parametric Analysis of Electrochemical Discharge Micro-Machining References Basak I and Ghosh A (1996), Mechanism of spark generation during electrochemical-discharge machining- A theoretical model and experimental verification, Journal of Materials Processing Technology, 62, Bhattacharyya, B., Doloi, B. and Sorkhel, S.K (1999), Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic material, Journal of Materials Processing Technology, 95, Fig. 15 Effects of Duty Ratio on HAZ area 4. Conclusions From the present parametric analysis, it can be evident that ECDM can be used with great potential to machine electrically non-conducting harder brittle materials such as glass and can also be employed for micro-channel cutting applications. Within the limitations of the developed ECDM system, the following conclusions can be drawn: (i) MRR increases with the increase of applied voltage, electrolyte concentration, duty ratio but decrease with pulse frequency when NaOH electrolyte is used for micro-channel cutting on glass with ECDM process. (ii) Overcut always increases with increase of applied voltage but it increases with increase of concentration upto 25wt% and with duty ratio from 55%. Also it decreases with increase of pulse frequency. (iii) HAZ area increases with increase applied voltage and with electrolyte concentration upto 25wt%. Initially HAZ area increases and then it decreases with frequency whereas it increases with duty ratio after 55% of duty ratio. Hence, this research work will be very helpful to manufacturing engineers during µ-profile generation on electrically non-conducting materials such as glass using advanced modern manufacturing processes. Acknowledgement The authors acknowledge the financial assistance provided by the CAS Ph-IV programme of the Production Engineering Department of Jadavpur University under the University Grants Commission, New Delhi. Cao X. D., Kim B. H., Chu C. N. (2009), Microstructuring of glass with features less than 100µm by electrochemical discharge machining, Precision Engg., 33, Han M. S, Min B. K., Lee S. J. (2007), Improvement of surface integrity of electrochemical discharge machining process using powder-mixed electrolyte, Journal of Materials Processing Technology, 191, Jain V.K., Dixit P.M., and Pandey P.M (1999)., On the analysis of the electrochemical spark machining process, Int. J. of Machine Tools and Manuf., 39, Jawalkar C.S., Kumar P. and Sharma A. K. (2012), On mechanism of material removal and parametric influence while machining soda lime glass using electro-chemical discharge machining (ECDM), 25 th AIMTDR Conference, pp Jui S. K., Kamaraj A. B., Sundaram M. M. (2013), High aspect ratio micromachining of glass by electrochemical discharge machining (ECDM), Journal of Manufacturing Processes,15, Kim, D.J., Ahn, Y., Lee, S.H. and Kim, Y.K. (2006), Voltage pulse frequency and duty ratio effects in an electrochemical discharge microdrilling process of Pyrex glass, International Journal of Machine Tools & Manufacture, 46, Sarkar. B. R, Doloi B. N and Bhattachryya B (2006), Parametric analysis on electrochemical discharge machining of silicon nitride ceramics, International Journal of Advanced Manufacturing Technology, 28,

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