Experimental Investigation on Micromachining using Electrochemical Discharge Machine

Jinka Ranganayakulu ME09S031 Guide Dr. Somashekhar S Hiremath

Precision Engineering and Instrumentation Laboratory Department of Mechanical Engineering Indian Institute of Technology Madras Chennai 600036

Contents
Introduction Literature survey Motivation Objective Proposed methodology Suggested course work References

Introduction
Types of machining processes: 1. Conventional (traditional) machining Tool must be harder than the work material The difficulty in adopting the traditional manufacturing processes can be attributed mainly to the following three basic sources: I. New materials with a low machinability II. Dimensional and accuracy requirements III. A higher production rate and economy With the conventional machining methods it is very difficult to machine harder materials used in aerospace industry, machining a complicated turbine blade made of superalloys, and producing holes and slots (both through and blind) in materials such as glass, semiconductors, nimonic alloys.

2. Un-Conventional Machining The problems faced with the Conventional Machining can be over come by using Un-Conventional Machining methods Here tool is softer than the work material Some of the un-conventional machining processes are: 1. Ultrasonic Machining (USM) - utilizes mechanical energy for material removal by erosion - for conducting and non-conducting materials 2. Abrasive Jet Machining (AJM) - utilizes mechanical energy for material removal by erosion - for conducting and non-conducting materials 3. Electrochemical Machining (ECM) - utilizes electrochemical energy for material removal by ion displacement - used for conducting materials.

4.

5.

6.

Electric Discharge Machining (EDM) - utilizes thermal energy produced by electrical spark for material removal by fusion and vaporization - used for conducting materials Laser Beam machining (LBM) - utilizes thermal energy produced by the powerful radiation - used for conducting and non-conducting materials Electrochemical Discharge Machining (ECDM) ECDM is a hybrid machining process comprises the techniques of both electrochemical machining (ECM) and electro discharge machining (EDM) This process mainly developed for machining hard, brittle and non-conducting materials like ceramics, glass etc., Micro features can be machined with ECDM

Basic elements of ECDM & Material removal mechanism

NaOH

Basic elements of ECDM Process

Material removal mechanism in ECDM

Electrochemical Discharge Phenomena

cathode

anode

W/P
0V

W/P
7.5 V

W/P
15 V

W/P
30 V

Reactions at the cathode (or tool) ( I ) Plating of metal ions The reaction for metal plating is: where M represents any anode material. ( ii ) Evolution of hydrogen gas. (in alkaline solution) Reaction at anode (auxiliary electrode) ( I ) Dissolution of metal ions in the electrolytic solution The anodic dissolution reaction is: ( ii ) Evolution of oxygen gas at the auxiliary electrode surface. ( in alkaline electrolyte solution )

Literature Survey
1) Indrajit Basak et al, has been analyzed the ECD phenomenon as a switching process between the tool (one of the electrodes) and the electrolyte and it has been found that an extra control parameter can be obtained by introducing an additional inductance in the circuit. B. Bhattacharyya et al, conducted experiments with ECDM on non-conductive ceramic materials and discussed the influence of electrolyte concentration, voltage and tool tip geometry on material removal rate (MRR) and condition of machined surface. V. Raghuram, discussed about various aspects about best electrical circuit configurations, the origin of light emitted by electrochemical discharge, methodology for detection of the temperature during discharge and modified machining of glass. R. Wuthrich et al , discussed about spark assisted engraving (SACE) and drilling holes on glass. Concluded that, material removal rates depend on a large number of parameters like material to be machined, used electrolyte, applied voltage and temperature.

2)

3)

4)

5.

6.

7.

W.Y. Peng et al , conducted study of electrochemical discharge machining technology for slicing non-conductive brittle materials, glass and quartz. They investigated the electrolyte supply for more stable and stronger spark release. The lower ambient pressure could evoke more drastic reaction. The power source is modulated to find the suitable parameters for different material properties being sliced under different energy intensity. Min-Seop Han et al , conducted studies on modeling gas lm formation in electrochemical discharge machining processes using a side-insulated electrode. In this study, a partially side-insulated electrode that maintained a constant contact surface area with the electrolyte was used for the ECDM process to ensure that a uniform gas lm was formed. Visual inspections indicated that the side-insulated tool provides new possibilities for describing the exact geometry of a gas lm by inducing single bubble formations. Y.P. Singh et al , conducted studies on Machining Piezoelectric (PZT) ceramics using an Electrochemical Spark Machining (ECSM) process. In this study, the authors have attempted to explore the feasibility of using an Electrochemical Spark Machining (ECSM) process for machining of electrically partially conductive materials like piezoelectric ceramics (namely Lead Zirconate Titanate PZT) and carbon fiber epoxy composites.

Motivation
From the literature survey it is understood that emphasis is made on producing macro features both on conducting and non conducting materials. A limited research work has been carried out in the production of micro features using electrochemical discharge machining (ECDM). Hence the present research work considers the production and study of micro features on non-conducting materials.

Objective
A prototype model of an Electrochemical Discharge Machine integrated with sensors is to be developed The investigation is to be carried out on various engineering materials-PZT, Magnetostrictive materials, composites , ceramics etc., The effects of process parameter are to be evaluated voltage, electrolyte concentration, tool geometry.

Proposed Methodology
The present research work will be focused on the machining of micro features on the non-conducting materials. The effective tool feed mechanism to be developed to achieve the required depth characteristics.
Study of existing literature Developing an experimental setup Robust design using Taguchy technique for optimizing the affecting process parameters Modeling the ECDM phenomenon-mathematical model Thermal analysis using finite element analysis Carrying out the experiments with various parameters arrived from Robust design Validation of simulation results with experimental data Preparation of report with conclusions

Suggested course work

Sl. No 1 2 3 4 Course No ME 7220 ME 7090 ME 7010 ME 7240 Course Name Metal Removal Processes Advanced Materials and Processing Micro Processors in Automation Modeling and Simulation in Manufacturing Core/Elective Year/Semester 2009-10/Even 2010-11/Odd 2009-10/Even 2009-10/Even

5
6 7 8

CT 7000
MM 5410 ME 6800 ID 6020

Composite Materials Science

Ceramic Science and Technology Finite Element Analysis Introduction to Research Compulsory

2010-11/Odd
2010-11/Even 2010-11/Odd 2009-10/Even

References
1. 2. 3. 4. 5. 6.

7.

8. 9.

J. A. McGeough, Principles of Electrochemical Machining, Chapman and Hall. London. P.C. Pandey and H.S. Shan, Modern Machining Processes, Tata McGrawHill Publishing Company Limited. P.K. Mishra, Non-conventional Machining, Narosa Publishing House. Gary F. Benedict, Nontraditional Manufacturing Processes, Marcel Dekkar, Inc. Samuel Glasstone, An Introduction to Electrochemistry, Affiliated EastWest Press Private Limited, New Delhi. J. Palo Davim (Editor), Machining Fundamentals and Recent Advances, Springer-Verlag London Limited. V.K. Jain (Editor), Lecture Notes of 3rd SERC School on Precision Engineering, June 10- 19, 2002, Organised by Department of Mechanical Engineering, Indian Institute of Technology,Kanpur-208016. V. Raghuram, PhD dissertation, IIT Madras. Indrajit Basak et al, Mechanism of spark generation during electrochemical discharge machining: a theoretical model and experimental verification, Journal of Materials processing Technology, Volume 62, 1996, pp. 46-53.

10.

11.

12.

13.

14.

15.

Indrajit Basak et al, Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification, Journal of Materials Processing Technology, Volume 71, 1997, pp. 350-359. B. Bhattacharyya et al, Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials, Journal of Materials Processing Technology, Volume 95, 1999, pp. 145-154. R. Wuthrich et al, Machining of non-conducting materials using electrochemical discharge phenomenonan overview. International Journal of Machine Tools & Manufacture, Volume 45, 2005, pp. 10951108. W.Y. Peng et al, Study of electrochemical discharge machining technology for slicing non-conductive brittle materials, Journal of Materials Processing Technology Volume149, 2004, pp.363369. Min-Seop Han et al, Modeling gas lm formation in electrochemical discharge machining processes using a side-insulated electrode, IOP Publishing, Journal of Micromechanics and Micro-engineering, J. Micromech. Microeng. Volume 18, 2008, 8pp. 045019. Y.P. Singh et al, Machining piezoelectric (PZT) ceramics using an Electrochemical Spark Machining (ECSM) process, Journal of Materials Processing Technology, Volume 58, 1996, pp.24-31.

THANK YOU