Abstract
Grinding assisted electrochemical discharge drilling (G-ECDD) is a novel technique for producing micro and macro holes in brittle materials including advanced ceramics and glass, both efficiently and economically. G-ECDD involves the use of a rotating diamond core drill as the tool in a normal electrochemical discharge machine setup. The material removal happens by a combination of thermal melting due to electric discharges, followed by grinding action of diamond grits and chemical etching action. In this study, the effect of process parameters like voltage, duty cycle, cycle time and electrolyte concentration on material removed (MR) was investigated systematically using response surface methodology. Analysis of variance was performed to identify the significant factors and their percentage contribution. The most significant factor was found to be duty cycle followed by voltage, cycle time and concentration. A quadratic mathematical model was developed to predict MR. Tool wear was found for different frequencies and voltages. Higher tool wear was observed for high frequency above 5kHz pulsed DC supply at high voltage of 110V. Tool wear at the end face of the tool was found to be a significant problem affecting the tool life.
Highlights
Grinding assisted electrochemical discharge drilling (G-ECDD) is a hybrid machining technique which utilizes the combined effect of electrochemical discharges, grinding action of diamond coated/impregnated tool along with high temperature chemical etching action of the electrolyte for removing material from the workpiece
The most significant factor was found to be duty cycle followed by voltage, cycle time and concentration
This study aims to reveal the performance of G-ECDD for machining glass and to find a practical solution to reduce the tool wear rate
Summary
Grinding assisted electrochemical discharge drilling (G-ECDD) is a hybrid machining technique which utilizes the combined effect of electrochemical discharges, grinding action of diamond coated/impregnated tool along with high temperature chemical etching action of the electrolyte for removing material from the workpiece. The rotating tool will be polarized as the cathode and a steel plate will be maintained as the anode Both the electrodes are dipped in an electrolyte and a pulsed DC voltage will be applied between the electrodes. The electrochemical reactions at the cathode liberates hydrogen bubbles which will combine to form a gas film at the critical voltage and the film separates the tool from the electrolyte. This develops high current density at the tool tip and causes ionization of the hydrogen gas inside the film. The rotating tool with diamond grits at its tip remove the molten material from the machining zone This reduces the heat affected zone and increase the MRR. Few researchers have conducted a systematic study of ECDM process using abrasive tools and there is a great need to unveil the full potential of G-ECDD through proper research strategies
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