Abstract
Electrochemical machining has great potential of machining of any HSTR metals due to its various advantages like free of tool wear, thermal, and residual stresses. The process of electrochemical milling is similar to conventional electrochemical machining (ECM). Here, a simple shaped tool follows a pre-identified tool path and material is removed by electrochemical reactions in a layer-by-layer approach. Electrochemical milling (EC milling) is extensively used for the fabrication of complex shaped features on various HSTR alloys so far due to its process simplicity and many superior advantages than conventional ECM process. Present research work looks into the influence of EC milling characteristics, e.g., tool feed rate and milling layer depth on various responses, e.g., overcut, surface roughness, and quality of machined profile by EC milling process. It was observed that EC milling with one molar solution of sodium chloride and sodium nitrate along with tool rotation generates accurate machined profiles with excellent surface finish on Nimonic-263 alloy.
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