Abstract
Grinding aided electrochemical discharge machining is a hybrid technique, which combines the grinding action of an abrasive tool and thermal effects of electrochemical discharges to remove material from the workpiece for producing complex contours. The present study focuses on developing fluidic channels on borosilicate glass using G-ECDM and attempts to develop a mathematical model for surface roughness of the machined channel. Preliminary experiments are conducted to study the effect of machining parameters on surface roughness. Voltage, duty factor, frequency and tool feed rate are identified as the significant factors for controlling surface roughness of the channels produced by G-ECDM. A mathematical model was developed for surface roughness by considering the grinding action and thermal effects of electrochemical discharges in material removal. Experiments are conducted to validate the model and the results obtained are in good agreement with that predicted by the model.
Highlights
Grinding aided electrochemical discharge machining is a hybrid technique, which combines the grinding action of an abrasive tool and thermal effects of electrochemical discharges to remove material from the workpiece for producing complex contours
He observed that the use of pulsed direct current (DC) reduced the cracking at high voltage and machining ability got improved with the abrasive tool
The material removed for different voltages and temperatures was found to be high for abrasive cutting tool (ACT) when compared with conventional cutting tool (CCT)
Summary
A portion of the material will be removed by chemical etching action in which the molten workpiece material reacts with the electrolyte to form complex compounds These combined mechanisms enhance the material removal rate and the grinding action of diamond grits remove the recast layer produced by solidification of molten material. An enhancement in MRR was observed with an extra inductance in the circuit They developed a mathematical model to predict MRR in electrochemical discharge machining of glass. Chak and Rao [2] performed trepanning of alumina by ECDM using an abrasive tool He observed that the use of pulsed DC reduced the cracking at high voltage and machining ability got improved with the abrasive tool. Ladeesh and Manu [4] performed drilling of borosilicate glass using G-ECDM and observed that thermal melting, grinding action and chemical etching are the different mechanisms contributing material removal. A mathematical model is developed to predict the surface roughness of the channels produced using G-ECDM
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