Electrochemical Micromachining (EMM) is a non-conventional technique that has the potential to provide excellent accuracy due to its ionic dissolution nature. The technique is evolving rapidly with continuous research works and emerging as a frontline technology in the micro-fabrication domain. The dominant input factors of electrochemical machining (ECM) process become very sensitive at micro-domain and parametric optimization is inevitable for enhanced performance. New researches are required to enhance every aspect of the processing system that includes electric power, electrolyte, feed mechanism, gap control etc. The aim of the current work is to produce micro-holes on SS-304 sheet using tungsten tool and citric acid electrolyte through EMM process. An EMM device fabricated for experimentation purpose with pulse generator was utilized in this research. The operating factors preferred for study are voltage, current, pulse-on-time & electrolyte concentration. Taguchi’s L9 design for trials and Grey Relational Analysis (GRA) for multi response optimization were employed. The optimum set of parameters obtained through GRA included 12 V,1.2 A, 15 ms of pulse-on-time period and 20 g/l of solution concentration. The most influential factor observed was pulse-on-time. Though machining was slow with citric acid as electrolyte, holes produced were of good accuracy.

Optimization and Effect Analysis of Sustainable Micro Electrochemical Machining Using Organic Electrolyte

This work involves producing micro holes on Inconel 625 alloy through Electrochemical micromachining (EMM) process. The input parameters investigated are supply voltage, electrolyte concentration and duty ratio. The cathode tool used is a conical tipped stainless steel needle and the electrolyte is acidified sodium nitrate solution. Taguchi design of L9 Orthogonal Array is followed for experimental work. The performance analysis is done through process responses such as machining rate and overcut. The experimental results have given the optimum parameter combination for higher machining rate as 16 V supply voltage, 35 g/lit electrolyte concentration and 45% duty ratio and for lesser overcut as 12V, 35 g/lit and 45% duty ratio. The influence of input parameters on the process is also studied. The multi-objective optimisation technique used has produced 12 V, 30 g/lit and 45% duty ratio as the ideal combination for achieving higher machining rate and lower overcut.

P.N. Mohan Kumar

Papers

Performance optimisation of electrochemical micromachining of micro-holes on Inconel 625 alloy