Abstract
Machining of low machinable non conducting engineering materials like borosilicate glass has imposed challenges in the manufacturing of micro devices like microfluidics, MEMS etc. Electrochemical discharge machining (ECDM), a hybrid processes of electric discharge machining (EDM) and electro chemical machining (ECM), emerging as a potential method to address the low machinability problems. In the present work the influence of helical tungsten carbide tools of varying diameter assisted with high speed tool rotation was adopted to improve machining performance in terms of on the material removal rate (MRR), heat affected zone (HAZ), radial over cut (ROC), tool wear rate (TWR) and depth of machining (DOM). It was found that the hydrodynamic region was more predominant with tool diameters 600 μm, 700 μm and at 2,500 rpm and resulted to a low machining depth. Smaller diameter tools assisted with rotational was found significant influence on the machining responses.
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