Experimental Investigation of the Effects of Electrode Shape on ECSM Performance during Machining of Alumina Ceramics
Advanced ceramic material like alumina ceramic is continuously gaining the industrial acceptance in various applications such as cutting tools, electrical and thermal insulators, turbine blades, electronic devices etc. due to the superior properties of such ceramic. The alumina ceramic has different superior qualities such as high hardness, refractoriness, wear and corrosion resistance, high temperature withstands capability, low thermal coefficient of expansion etc. But machining of alumina ceramics is very difficult because of its brittleness and electrically nonconductive. Keeping in view, the present research work undertakes the machining study through design and fabrication of electrochemical spark machining (ECSM) setup. Experiments were carried out with three different shapes of electrodes such as (i) solid circular shape of 0.8mm diameter (ii) hollow circular shape of 0.8mm external and 0.6mm internal diameter (iii) 0.8mm diameter solid circular tool with flutes i.e. drill type electrodes. The experimental results and SEM images of the machined holes revealed that the solid circular drill electrode is better electrode as compared to the others electrodes used for experiments for machining of hole on alumina ceramic workpiece specimens. The working range of different machining parameters was also identified on the basis of experimental results and analyzed the effects of ECSM set-up parameters on response characteristics.
Jain V. K., Choudhury S. K., & Ramesh K.M. (2002). On the machining of alumina and glass. International Journal of Machine Tools & Manufacture, 42, 1269–1276.
Mohd Abbas N., Solomon D.G., & Fuad Bahari M. (2007). A review on current research trends in electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture, 47(7–8), 1214-1228.
Bhattacharyya B., Mitra S., & Boro A.K. (2002). Electrochemica l machining: New possibilities for micromachining. Robotics and Computer-Integrated Manufacturing, 18(3–4), 283-289.
Wuthrich R. & Fascio V. (2005). Machining of nonconducting materials using electrochemical discharge phenomenon— An overview. International Journal of Machine Tools & Manufacture, 45(9), 1095–1108.
Jain V. K. & Adhikary S. (2008) On the mechanism of material removal in electrochemical spark machining of quartz under different polarity conditions. Journal of Material Processing Technology, 200, (460-470).
C.T. Yang, S.L. Song, B.H. Yan & F.Y. Huang. (2006). Improving machining performance of wire electrochemical discharge machining by adding SiC
abrasive to electrolyte. International Journal of Machine Tools & Manufacture, 46, (2044-2050).
Manna A. & Kundal A. (2015). An experimental investigation on fabricated TW-ECSM during micro slicing of non conductive ceramic. The International Journal of Advanced Manufacturing Technology, 76(1-4), 29-37.
Manna A., & Narang V. A. (2012). Study on micro machining of e-glass–fibre–epoxy composite by ECSM process. The International Journal of Advanced Manufacturing Technology, 6, (1191–1197).
Eunice S.L.D., Howard E., Liang S., Collins D., Rosemary, & Smith L. (2004). Removable tubing interconnects for glass-based micro-fluidic systems made using ECDM. Journal of Micromechanics and Micro Engineering, 14(4), 535-540.
Yang C. K., Wub K. L., Hung J. C., Lee S. M. , Lin J. C., & Yan B. H. (2011). Enhancement of ECDM efficiency and accuracy by spherical tool electrode. International Journal of Machine Tools & Manufacture, 51, (528–535).
Wei C., Xu K., Ni J., Brzezinski A. J., & Hu D., (2011). A finite element based model for electrochemical discharge machining in discharge regime. The International Journal of Advanced Manufacturing Technology, 54(9-12), 987-995.
Copyright (c) 2018 International Journal of Engineering and Management Research
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.