Mathematical Modelling of Material Removal Rate and Diameter of overcut for Sodalime glass through pressurized flow ECDM Process by Response Surface Methodology

Abstract

The effect of electrolyte concentration, voltage, duty factor and electrolyte flow rate on material removal rate (MRR) and diameter of overcut (DOC) of the micro-hole machining of sodalime has been studied. The experimental values changed with the theoretical calculation in the range of 3 – 10 %. This mathematical model showed that decreasing electrolytic concentration reduces MRR and DOC. Pressurized flow Electrochemical DischargeMachining (pf-ECDM) can meet these differences. In order to put this phenomenon to use many experiments were experimented to machine holes on glass. Since parameters like electrolyte concentration, voltage, duty factor and electrolyte flow rate play an important role in MRR and DOC it needs to be calculated in order to improve the capability of this technology in machining difficult and high aspect ratio features. A mathematical model has been extensively developed to know the role of electrolyte concentration, voltage, duty factor and electrolyte flow in MRR and DOC of the process. However, machining excessive component ratio elements on ceramics like glass stays an ambitious challenge due to overcut. Although, electrical discharge machining (EDM) and electrochemical machining (ECM) are properly set up non-traditional strategies to meet these challenges, they are restrained to electrically conductive materials. In order to execute functionalities like excessive power and sustainability with minimal use of space, the raw substances used need to possess desirable mechanical, chemical and physical properties. Experimental research has been conducted, and the model was proven below various machining parameters. Demand for miniaturized merchandise is ever growing as they accomplish the venture of supplying the preferred functionalities with high efficiency using minimalistic raw material. These researches proved that growing the voltage in pf-ECDM plays a primary function in growing the MRR of the machined features.