Width Overcut Research Articles

Real-time monitoring of process current and its correlation with micro-feature accuracy and surface topography in electrochemical micromachining of nitinol

The nickel-titanium alloy known as Nitinol classified as a shape memory alloy is distinguished by its exceptional attributes, including shape memory effect, biocompatibility, and superelasticity. However, its thermo-mechanical dependent transformation behavior makes it difficult to process using traditional methods. Electrochemical micromachining (ECMM), a non-traditional fabrication method, uses anodic dissolution process to produce microfeatures on Nitinol. The current work emphasizes the impact of process current on the machining accuracy and surface topography of microchannels produced during ECMM of Nitinol utilizing ethylene glycol-based sodium nitrate electrolyte. The ECMM process parameters that were studied are pulsed potential, molar concentration, and micro-tool scan rate, and the development of the process current resulting in variation of these parameters during microchannel fabrication was closely observed. The statistical parameters, namely, the average process current and the process current fluctuation, were derived from the process current data that were further analyzed with respect to input parameters. The machining accuracy and the surface topography of the microchannel are analyzed by measuring the width overcut, channel depth, stray region, width standard deviation, and average surface roughness of the fabricated microchannel. The results showed that monitoring the process current in real-time is an effective way of controlling the process, particularly when it comes to fabricating micro-features that must adhere to strict predetermined criteria.

Electrochemical Characterization and Micromachining of Nitinol SMA by WECM Using Citric Acid Mixed H2SO4 Electrolyte

Nitinol shape memory alloy (SMA) is a tough material to machine because it is difficult to cut. The results of the current research work demonstrate how two different electrolytes affect the electrochemical behavior in relation to electrochemical machining performance of nitinol. Potentiodynamic polarisation (PDP) and electrochemical impedance spectroscopy (EIS) tests have been conducted using 0.1 M H2SO4 and mixed 0.1 M H2SO4 + 0.1 M citric acid electrolyte. Further, the experimental investigation on the machining characteristics of nitinol during wire electrochemical machining (WECM) has been conducted. It is revealed that the grooves width and depth increase with increase in applied pulse voltage and surface roughness increase with increase in groove depth. The minimum width overcut of machined groove was 18.10 μm in 0.1 M H2SO4 + 0.1 M citric acid at 5 V pulse voltage which is less compared to width overcut of 24.85 μm produced in 0.1 M H2SO4 electrolyte for same parametric machining condition. This specific mixed electrolyte produced average surface roughness (Ra) of 0.0631 μm at 5 V which is lower compared to 0.09055 μm produced using 0.1 M H2SO4 electrolyte. The fabrication of homogeneous average slit width of 92.234 μm using citric acid mixed H2SO4 electrolyte with minimum average surface roughness (Ra) of 0.0691 μm shows the capability of WECM.

Experimental Investigation and Modelling Studies on MHD Convection in Magnetic-assisted -ECDM

ABSTRACT The present work concerns microchannel fabrication using magnetic-assisted electrochemical discharge machining on silica glass. The magnetic field regulates the process by controlling bubble formation and separation adjacent to the tool edge. Due to the applied magnetic and electric flux on the electrolyte and electrode interface, the Lorentz force impacts the bubble establishment and film quality. The fractional bubble coverage decreases with the magnetic field, which increases the current density and affects the discharge frequency. The analytical model is explored here to investigate the magnetic field influences on departure radius. A novel approach has been adopted to couple the Laplace and Navier stokes equations for studying the magnetohydrodynamic effect. The experimental and analytical results reveal that magnetic flux decreases the bubble departure radius. The regression model explains the impact of controllable factors on surface roughness, material removal rate, and width overcut. The multi-response optimization with the hybridization of response surface methodology and grey relation analysis technique provides the optimum value of material removal rate, width overcut and surface roughness as 1.2 mg/min, 0.046 mm, and 1.58 µm, respectively.

Assessing the performance of air, argon, and oxygen as dielectric mediums during dry-micro-EDM of Ti6Al4V alloy: A comparative study

ABSTRACT Due to sheer environmental risks associated with hydrocarbon-based dielectric media, their use is discouraged not only in manufacturing processes but also throughout all commercial operations to meet the Sustainable Development Goals. Therefore, continuous research efforts are being made to find an alternative to hydrocarbon-based EDM oil. The current work is an attempt in the same direction, wherein the use of alternate dielectric media during EDM of micro-grooves on Ti6Al4 V alloys has been investigated. The performance of three dielectric gases, air, argon, and oxygen, has been evaluated. To predict the parametric relationship, investigations have been performed by altering pulse current along with pulse-on/off times by utilizing the response-surface-methodology. The material removal mechanism for different gases is expounded using analysis of debris, single-discharge crater, and recast-layer. Using oxygen instead of air or argon yielded about 19% and 51% quicker material removal rate (MRR) for identical parameters. On the contrary, using argon instead of air and oxygen yielded roughly 17% and 34% less roughness and nearly 17% and 34% less width over-cut, respectively. Optimization results showed that oxygen rendered a maximum MRR of mm /min, which is almost three times that of argon. Splat-like surface features were observed on the machined surface for oxygen.

Study of the electrochemical dissolution behavior of Nitinol shape memory alloy in different electrolytes for micro-ECM process

Nickel-titanium alloy (Nitinol) is an excellent shape memory alloy (SMA) for microelectro-mechanical systems (MEMS) particularly in biomedical applications owing to its three excellent features shape memory effect (SME), superelasticity, and biocompatibility. The temperature-dependent material transformation properties of Nitinol SMAs make conventional machining difficult. Micro-ECM, a non-conventional machining process for conductive materials regardless of their strength and hardness, has the potential to fabricate microfeatures on Nitinol. This study presents the investigation on the electrochemical dissolution behavior of Nitinol in different electrolytes for micro-ECM. The influence of electrolytes on the nature of dissolution of Nitinol was studied by fabricating microchannels in three levels of parameters containing applied voltage and electrolyte concentration. The first three electrolytes were all aqueous neutral electrolytes, i.e., NaCl, NaNO3, and NaBr. The aqueous NaNO3 was successful in fabricating microchannels at all levels of process parameters. However, aqueous electrolytes form relatively a huge amount of sludge on the machined surface reducing both dissolution efficiency and machining accuracy. Thus, ethylene glycol-based NaNO3 was used to fabricate microchannels with lower depth overcut (DOC), width overcut (WOC), and length overcut (LOC) with respect to aqueous NaNO3 electrolyte. The potentiodynamic polarization (PDP) tests of Nitinol through cyclic voltammetry (CV) shows passive dissolution in aqueous electrolyte and active dissolution in non-aqueous electrolyte.

Research on ultrasonic vibration–assisted electrical discharge machining SiCp/Al composite

In this paper, ultrasonic vibration–assisted electrical discharge machining (UEDM) is used to process SiCp/Al composite materials in order to achieve a higher material removal rate (MRR) and lower surface roughness, width overcut, and relative tool wear rate (RTWR). On the basis of studying the erosion mechanism of EDM SiCp/Al composite material, the flow field simulation study was carried out using FLUENT software. The simulation results of the gap flow field show that the ultrasonic vibration of the tool electrode is conducive to the removal of chips, which makes the discharge more stable and improves the machining efficiency. Based on the single-factor experiment, the effects of peak current, reference voltage, pulse width, and pulse interval on MRR, surface roughness, width overcut, and RTWR of the workpiece are studied. Then, based on the orthogonal experiment, the gray relational analysis method was used to optimize the process parameters, and the order of the influence of the 4 process indicators on the comprehensive performance and the optimal processing parameter combination was obtained. The reliability of the process optimization was verified with experiments.

Electrochemical Micromachining of Linear Micropattern on Stainless Steel Surface

Maskless electrochemical micromachining process with SU-8 2150 masked tool has been introduced containing microstructures with higherprofile accuracy that are generated on SS-304. In this research work, to make maskless EMM method with more cost-effective, substantial adaptations are provided to this technique and an advanced version of EMM process is applied for microtexturing. In this modified technique, a special microtextured cell unit including (micromachining cell, electrical connection, and electrolyte flow scheme) is assembled by the mechanical force and perpendicular cross flow system has been developed inside the cell. Experimentation is conducted to explore the machining influence of the advanced maskless EMM process for fabricating linear micropattern. The machining outcomes of voltage, frequency, and duty ratio on MRR, dimensional accuracy, textured depth, and surface roughness are investigated during microtexturing. The investigational research reveals that this advanced maskless EMM technique can generate highly identical micropatterns having MRR of 2.2 mg/min, width overcut of 19.76μm, textured depth of 14.4μm and surface roughness of 0.0307μm.

Generation of high aspect ratio complex micro-features by micro-electrochemical milling employing novel flushing technique

Fabrication of high aspect ratio (HAR) complex micro features on high strength temperature resistant (HSTR) alloys is challenging by any conventional or non-conventional machining methods. In this study blind, HAR and complex micro features have been fabricated by micro electrochemical milling (MEM) on HSTR Cobalt alloy (Haynes-188) introducing a new strategic approach with novel flushing technique which could get rid of the need of pulsed DC power supply. Multiphysics simulation of the rotating micro-tool at different rpm and its impact on effective sludge removal has been analyzed and verified experimentally. In this study, most influencing parameters of MEM like voltage, feed rate, rpm of tool and milling layer depth have been selected to investigate their effects on the machining responses like width overcut, machined depth and surface roughness on Haynes-188 alloy. Comparison has also been made with constant and pulsed DC power source to know the influence of these process parameters on the MEM responses. Finally, several linear and non-linear blind, HAR (AR > 11) and intricate micro features have been fabricated successfully on cobalt alloy at the most suitable parametric combination, i.e., 7.5 V of machining voltage, feed rate of 0.3 mm/min, and tool rotation of 750RPM with 0.5 M of NaNO3 electrolyte.

Experimental Investigations into Electrochemical Milling of Ti6Al4V During Generation of Three-Dimensional Features

This research work investigates the influence of process parameters e.g. feed rate and milling layer depth with tool rotation on various performance criteria e.g. overcut, machining depth, perpendicularity, radius of curvature of the side wall and surface roughness during electrochemical (EC) milling of Ti6Al4V with the indigenously developed setup. In this study, three most accepted multicriteria and decision-making (MCDM) techniques e.g. SAW, TOPSIS and MOORA are utilized for finding out the optimal parametric combination followed by fabrication of different three-dimensional complex features on Ti6Al4V at that optimal parametric combination. This study confirms that internal flushing with tool rotation improves the accuracy of the machined profile due to better removal of sludge from the machining zone. Developed milling setup is able to generate different complex and three- dimensional features on Ti6Al4V with desired accuracy. Using 1[Formula: see text]M of NaNO3 and NaCl mixed electrolyte, at 4.4[Formula: see text]mm/min of feed rate and 0.25[Formula: see text]mm of milling layer depth with tool rotation, best values of width overcut, average depth, side angle, radius of curvature and surface roughness ([Formula: see text] are achieved as 0.666[Formula: see text]mm, 1.538[Formula: see text]mm, 47∘, 2.091[Formula: see text]mm, and 1.462[Formula: see text][Formula: see text]m, respectively.

Influence of Various Pulse Waveforms during Fabrication of Micro Rectangular Pattern by Masked Tool using Electrochemical Micromachining

Maskless electrochemical micromachining (EMM) is an alternative method to fabricate microsurface textures on conductive substances, but it is still very challenging issue to create microsurface textures by this method. This paper proposes a new issue that maskless EMM process generates micro rectangular patterns using various pulse waveforms i.e. triangular, sine and square of pulsed DC power supply at constant voltage mode on stainless steel (SS-304) workpiece. A novel concept of maskless EMM setup consisting of EMM cell, electrode holding devices, electrical connections and vertical cross flow electrolyte system is introduced for the generation of high-quality micro rectangular patterns using various pulse waveforms. Another important finding is that SU-8 2150 negative photoresist can fabricate more than 28 micro rectangular patterned samples with higher dimensional accuracy and surface quality. The influence of machining voltage, inter electrode gap, pulse frequency, duty ratio and flow rate is investigated on machining performance such as length overcut, width overcut, machining depth and surface roughness ([Formula: see text] of micro rectangular pattern using three pulse waveforms. One mathematical model is developed to show the effectiveness of three pulse waveforms by the estimation of current efficiencies. From the experimental investigation, it is observed that higher frequency with square waveform at constant duty ratio is suitable to generate high-quality micro rectangular patterns under pulsed DC power supply.

Influence of maskless electrochemical micromachining process parameters during fabrication of complex micropattern

Abstract Micropattern performs an elementary role in advanced microengineering fields, allowing for the enhancement of their function and performance criteria of various mechanical components. Maskless electrochemical micromachining (EMM) is an achievable substitute for creating complex micropatterns. However, this method is used to produce complex cascade micropattern with high quality surface characteristics. This research work is concentrated on generating cascade micropattern using a thick mask. The micropatterning setup is developed with micropatterning cell, electrolyte flow scheme and power supply connection. The single thick mask is reused for fabricating lots of intricate micropatterns. For reuse, the masked tool is generated using SU-8 2150 mask measuring 213 µm in thickness. The developed perpendicular cross flow electrolyte scheme is the unique feature for producing high quality micropattern. Furthermore, the outcomes of the machining voltage, micropatterning time and duty ratio on formation of complex microtextures are experimentally explored. The investigational consequences reveal that the dimensions of microtextures are mostly influenced by EMM process variables. The experimental results demonstrate that the best magnitudes of MRR of 0.0921 mg/sec, width overcut of 23.1 µm, depth of 12.8 µm and surface roughness of 0.0187 µm are produced in good quality complex micropattern.

Fabrication of cascade micropattern by maskless electrochemical micromachining

Cascade micropattern is the basic complex textured surface, which is generated on different microdevices for various advanced micromanufacturing applications. This paper highlights the experimental analysis into generation of cascade micropatterns on stainless steel (SS 304) by maskless electrochemical micromachining (EMM). The experimental setup consisting of electrode fixtures, EMM cell, power supply unit and electrolyte flow system is indigenously developed for fabrication of cascade micropatterns inexpensively without fabrication of one by one complex microfeature of cascade profile by a single microtool. One textured tool with SU-8 2150 mask can fabricate more than 25 cascade micropatterns. Influences of EMM parameters such as electrolyte concentration, electrolyte flow rate, pulse frequency and inter electrode gap on depth, width overcut and surface roughness (Ra) are studied during generation of cascade micropattern. An attempt has also been done to analysis the micrographs of generated cascade micropattern for investigating the suitable parameter setting. This investigation will be needful and fruitful for machining of need-based cascade micropatterns on microdevices like micromixers, microactuators, microcoolers, etc.

Fabrication of cascade micropattern by maskless electrochemical micromachining

Cascade micropattern is the basic complex textured surface, which is generated on different microdevices for various advanced micromanufacturing applications. This paper highlights the experimental analysis into generation of cascade micropatterns on stainless steel (SS 304) by maskless electrochemical micromachining (EMM). The experimental setup consisting of electrode fixtures, EMM cell, power supply unit and electrolyte flow system is indigenously developed for fabrication of cascade micropatterns inexpensively without fabrication of one by one complex microfeature of cascade profile by a single microtool. One textured tool with SU-8 2150 mask can fabricate more than 25 cascade micropatterns. Influences of EMM parameters such as electrolyte concentration, electrolyte flow rate, pulse frequency and inter electrode gap on depth, width overcut and surface roughness (Ra) are studied during generation of cascade micropattern. An attempt has also been done to analysis the micrographs of generated cascade micropattern for investigating the suitable parameter setting. This investigation will be needful and fruitful for machining of need-based cascade micropatterns on microdevices like micromixers, microactuators, microcoolers, etc.

Study of Micro-groove Generation on Titanium Alloy (Ti6Al4V) using Novel WEDM and WECM Sequential Electro Micro Machining (SEMM) Technique

Abstract The micro-part manufacturing can be accomplished by the execution of different micro-machining techniques. The sequential machining is one of the most promising techniques which dictate the structured approach towards the fabrication of highly precise micro-features in sophisticated components. The newly coined Sequential Electro Micro Machining (SEMM) technique has been implemented for the improvement of overall machining efficiency and enhancement in surface characteristics of the part during machining. In the chain of sequential machining, the present research paper has introduced a novel sequential combination of micro Wire Electro Discharge Machining (µWEDM) and micro Wire Electro-Chemical Machining (µWECM) processes. The µWEDM process was carried out on the standard wire cut EDM machine, whereas µWECM was performed on indigenously designed and developed system setup. The micro-grooves on difficult to cut material such as titanium alloy (Ti6Al4V) was initially generated by applying µWEDM process. The µWEDM is a thermal process, where the shaping of micro-groove was accomplished rapidly due to the existence of high-intensity spark discharges. The spark produced also generates recast layer comprising of cracks, micro-pores and numerous micro-craters in the heat affected zone of the machined region. During experimentation, the micro-groove using µWEDM process was cut at different machining voltages. In order to make out the best sequential machining combination, the machining voltage at which the least surface defects occurred on micro-groove was selected for sequencing with the subsequent process. In present experimentation, the least width overcut of the groove was obtained at 10V. The µWECM process was then applied to ameliorate the surface defects and other irregularities imparted to micro-groove during the µWEDM process. The effects of machining process parameters in µWECM, such as applied voltage, machining time and duty ratio on µWEDMed part was investigated. The sequential machining experiments were then conducted by choosing the best input process parameters in both the processes. The experimental results thus obtained after the application of diversified sequential micro-machining processes revealed an improved machining efficiency and high surface quality of micro-groove. Thus the µWEDM process for shaping the groove and µWECM process for finishing the groove was conducted successfully

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

The tool wear affects the efficiency of micro-USM process and the quality of machined micro-features. In this research endeavor, wear mechanism of soft/ductile and hard/brittle tool materials is investigated comprehensively. Stainless steel-304 (SS-304) and tungsten carbide (WC) were selected as tool materials for rotary tool micro-USM (RT-MUSM) process. The effect of tool material properties on tool wear and performance of RT-MUSM process is also discussed. The effect of RT-MUSM process parameters, viz. rotation speed, feed rate, power rating and slurry concentration on material removal rate (MRR), depth of channel (DOC) and width over cut (WOC) are reported. The experimental results showed that SS-304 tool worn out rapidly due to plastic deformation followed by strain hardening. The superior properties of WC such as high wear resistance, compressive strength and good acoustic property led to reduction in tool wear and thereby significantly improved the performance of RT-MUSM. Additionally, multi-response optimization was applied to obtain maximum MRR, DOC and minimum WOC simultaneously.

Investigation into fabrication of microslot arrays by electrochemical micromachining

Maskless electrochemical micromachining (EMM) is a prominent and unique surface texturing method to fabricate the arrays of microslots. This article investigates the generation of microslot arrays using maskless EMM method. The developed prototype maskless EMM setup consists of EMM cell, power supply connections, electrode holding devices and constricted vertical cross flow electrolyte system for the fabrication of microslot arrays economically. One textured cathode tool with SU-8 2150 mask is used to produce 22 microslot arrays. Influences of EMM process parameters including voltage, electrolyte concentration, inter electrode gap, flow rate and machining time on the machining performance that is, width overcut, depth and surface roughness (Ra) of microslot arrays are investigated. For lower width overcut, controlled depth, and lower surface roughness, machining with lower voltage, lower electrolyte concentration, lower inter electrode gap, higher flow rate and lower machining time are recommended. From the analysis, it is observed that the best machining conditions including inter electrode gap of 50 μm, applied voltage of 6 V, electrolyte concentration of 20 g L−1, flow rate of 5.35 m3 hr−1 and machining time of 1 min fabricate regular microslot array with mean width overcut of 24.321 μm, mean machining depth of 10.7 μm and mean surface roughness of 0.0101 μm.

Fabrication of various micropatterns by maskless micro-electrochemical texturing

In this paper, an innovative and alternative concept of maskless micro-electrochemical texturing is exploited for the fabrication of simple and complex micropatterns. In this process, the tool is masked incorporated with the textured patterns and the workpiece has no mask. This research study concentrates on generation of simple micropattern, i.e. linear micropattern, and complex micropattern, i.e. cascade micropattern using maskless micro-electrochemical texturing method without repeated use of photolithography process. A single masked patterned tool with SU-8 2150 mask can produce many high-quality simple and complex micropatterns economically using this method. A well-planned experimental set-up consisting of electrochemical micromachining (EMM) cell, electrode fixtures, electrical connections and constricted vertical cross-flow electrolyte system has been designed and developed indigenously for carrying out the experiments. Influences of major influencing parameters, i.e. machining voltage, interelectrode gap, flow rate and machining time, are investigated on width overcut and machining depth of micropatterns. For higher machining accuracy, controlled depth and lower standard deviations, machining with lower machining time, lower voltage, lower interelectrode gap and higher flow rate is recommended. From the detailed experimental investigation, the best parametric combination are voltage of 8 V, duty ratio of 30%, pulse frequency of 15 kHz, electrolyte of NaCl (0.34 M) + NaNO3 (0.23 M), flow rate of 5.35 m3/h, interelectrode gap of 50 µm and machining time of 40 s.

Experimental investigations into triplex hybrid process of GA-RDECDM during subtractive processing of MMC’s

ABSTRACTThe use of Al-6063 SiCp metal matrix composites (MMCs) in electronic packaging applications, heat sinks for printed circuit boards and for microwave housings necessitates certain degree of machining operations to meet the specifications of the product. The various conventional and non-conventional machining processes had been used to machine the MMCs. But all such processes have their limitations in providing the desired outcomes. Therefore, the present research endeavor, a new process variant of ECDM for the machining of Al-6063 SiCp MMCs. The developed grinding assisted rotary disk electrochemical discharge machining (GA-RDECDM) process integrates the concept of triplex hybridization. In GA-RDECDM, an abrasive coated rotary disk was used as a tool electrode. The abrasive coated disk provides micro gaps between the tool electrode and work material surface and thereby it results in thin and stable gas film formation. The breakdown of thin and stable gas films produce high frequency, low intensity discharges and consequently improves the machining performance. The additional abrasion action imparted by rotating disk ensures the continuation of ECDM process. The influence of various process parameters including applied voltage, pulse on time, electrolyte concentration and the disk rotation rate on width over cut (WOC) and depth were experimentally investigated. Multi criteria optimization using desirability approach predicts the parametric combination of applied voltage of 99V, pulse on time of 3 ms, electrolyte concentration of 17%wt./vol. and disk rotation rate of 30 rpm as the optimum setting for fabrication of slits on the MMCs. The underlying process mechanism is also investigated and presented with appropriate illustrations. The major contribution of the present research work is the development of a novel method for the fabrication of the slits on MMCs.

On performance evaluation of textured tools during micro-channeling with ECDM

Electrochemical discharge machining (ECDM) is an emerging technique for machining of micro-channels on non-conductive materials. It utilizes a combination of chemical as well as thermal energies to machine the materials. The configuration of tool electrode plays important role to channelize these energies from tool electrode to work material. Thus, the appropriate selection of tool electrode configuration is essential to effectively utilize the energies during ECDM for achieving machining accuracy. The present investigation reports on textured tools for machining of micro-channels on borosilicate glass with ECDM. The underlying process mechanism is investigated. Textured tools provides micro gaps between the tool electrode and the workpiece surface and results in thin and stable gas films. The breakdown of thin and stable gas films produces high frequency low intensity discharges and consequently improves the machining performance. The textured tools in comparison with smooth surfaced tools exhibits improvements in material removal rate (MRR) by 19.27% and depth by 64.81%. Also the width overcut (WOC) and surface roughness were reduced by 122.26% and 26.96%, respectively. The flexibility to develop textured as well as smooth micro-channel surfaces by textured tools provides wider scope for fabrication of various micro fluidic devices. The effect of ECDM process parameters (voltage, pulse on-time, pulse off-time, feed rate and electrolyte concentration) with the use of textured tools was investigated. Multi criteria optimization using desirability approach predicted the parametric combination of applied voltage of 59 V, pulse on-time of 3 ms, pulse off-time of 3 ms, feed rate of 12 m m/min. and electrolyte concentration of 21%wt./vol., the optimum setting for micro-channelling by ECDM using textured tools.

On performance studies during micromachining of quartz glass using electrochemical discharge machining

The electrochemical discharge machining is a highly stochastic process involving a number of complex parameters. Controlling of these process parameters simultaneously to fetch the best possible performance is a difficult task. Determining an optimal parametric combination has become complex owing to interdependency of the parameters. In this work, the authors have made an attempt to establish the optimal combination of control parameters for machining of micro-channels on quartz glass. Taguchi’s standard orthogonal array (L9) with Grey relational analysis (GRA) approach was used to establish the optimal parametric conditions for reducing the Width overcut (WOC) of micro-channels and increasing the Material removal rate (MRR). In order to optimize MRR and WOC together, the optimal combination of the selected control variables was obtained using the GRA. The experimental results showed the effectiveness of the adapted method to indicate the performance of the electrochemical discharge machining process.