Experimental Studies in Micro Channelling on Borosilicate Glass Using RSM Optimization Technique

Abstract

The electrochemical discharge machining (ECDM) is a preferred process for micromachining non-conducting materials since it has several desirable properties such as good material removal rates and surface roughness. It is an emerging technology having numerous applications. It is a thermal process, which produces some heat affected zones, which lead to lower thermal conductivity and higher chemical reactivity within the electrolyte. These properties lead to a reduction in tool life, while machining. In the presented work, ECDM was employed in machining borosilicate glass, and the technique of “Response Surface Methodology (RSM)” was attempted. Using different process parameters, i.e., applied voltage, electrolyte concentration, tool feed and tool rotation; optimization was carried out. Thus the relations between input and response parameters have been established for minimizing the values of tool wear (cathode and anode wear). RSM results illustrated good agreement with the experimental values. Scanning electron microscopy (SEM) was carried out for closely investigating the heat affected zones. In the illustrated experimnental condictions, tool wear (0.5 mg) and material removal (2.5 mg) were the most influencing parameters amongst others.