Ecdm finalppt
- 1. Project Progress Presentation on "Design and Development of Electro Chemical Discharge Machining." By SAURABH SHARMA (Roll No-1713340107) MANAV SHEEL (Roll No-1713340057) UBAISH QURAISHI (Roll No-1713340129) MOHD ZAID (Roll No-1813340916) Under the supervision of Mr. Rakesh Kumar (Head of Department) Department of Mechanical Engineering Noida Institute of Engineering and Technology Greater Noida, Uttar Pradesh - 201306 Affiliated to Dr. A.P.J. ABDUL KALAM UNIVERSITY, LUCKNOW (U.P.) July, 2021
- 2. TABLE OF CONTENTS • Introduction • Literature Review • Research Gap and Problem Formulation • Objective • Design/Fabrication/Experimental setup/Material and Equipments Used • Procedure • Results and Analysis • Labs Certificates of Tests • Conclusions and Future Scope • Research Publication out of the Present Work. • References
- 3. INTRODUCTION • Electrochemical discharge machining (ECDM) is one of the widely accepted hybrid non- conventional micro machining techniques, which is used to fabricate miniaturized products on electrically conductive and nonconductive materials. • It has potential to machine electrically conductive materials at a rate, five to fifty times higher than ECM & EDM and is also popular to machine electrically nonconductive, High-Strength- High-Temperature Resistant (HSHTR). • Materials like ceramics, quartz, glass, composites, etc.
- 4. Serial Number Title Source/Author Findings 1. Electrochemical discharge abrasive drilling (ECSAD) Jain et al To enhanced capabilities of process. Author found use of abrasive improved the process performance. The workpiece used was alumina & Borosilicate glass. 2. Microtool vibration system which consist of tool holding unit. Bhatt charyya Experiments to found out effective values of process parameters such as micro tool vibration frequency, amplitude and electrolyte concentration. Author found lower electrolyte concentration (15-20 gm/lit) decreases stray effect. 50- 200 HZ range of frequency is good for machining of narrow gap. 3. 3D finite element transient model Panda & Yadava to estimate temperature field & material removal rate due to Literature Review
- 5. Serial Number Title Source/Author Findings 4. Develop model of MRR by use of finite element method Bhodwe et Author found that model predict experimental result in range of accuracy. Also parametric study of electrolyte concentration, duty factor & energy partition was carried out. 5. ECSM by electrochemical approach Fascio et al Author propose two models of ECSM phenomenon based on percolation theory and another to estimate the discharge characteristic with the help of experimental data. In another paper Fascio et al done 3D micro-pattering with electro discharge assisted etching at tool tip. 6. Electrolyte viscosity Ziki et An important factor amongst others like voltage, tool-work piece gap, and tool travel
- 6. Serial Number Title Source/Author Findings 7. Experimented with soda lime glass 2 mm thick for microchannel drilling using NaOH and NaN03 electrolyte Jawalkar et al Machining using SS304 tool of 0.8 mm diameter and feed rate of 0.2 mm/min for 5 min was carried out. It was observed that NaOH was more effective than NaN03 for MRR. Electrolyte concentration, applied voltage, electrodes distance and time of current flow were all significant with voltage being the most important parameter at 70.18%. There was a substantial increase in MRR when using NaOH electrolyte at 50 V and tool wear was also found to increase beyond 50 V. 8. FESEM using NaOH Debris the presence of C, O, Na, Mg etc. and also iron due to the reaction with the tool.
- 7. Serial Number Title Author/Source Findings 10. Travelling wire electrochemical discharge machining (TWECDM) Peng & Liao Slicing non conductive brittle material (optical glass & quartz bars) of size 10 to 30 mm diameter. 11. The need of a refined model for ECDM process Jiang et al Modeled the gas film formation right from the bubble growth, bubble departure, gas film formation and the gas film in electrolysis. Using a cylindrical tool of 0.5 mm in diameter studies were conducted using 30 wt% NaOH. A high speed camera of 10 fps was used to record the gas film formation phenomena. They conclude that a thin gas film is desirable for lowering the critical voltage and the
- 8. What is ECDM? • Electrochemical discharge machining is the combination of Electric discharge machining (EDM) and Electrochemical machining (ECM) process. • Electrochemical discharge machining (micro ECSM) is an emerging non-traditional fabrication method capable of micromachining ceramic materials like glass, quartz, ceramics etc. • It is a preferred process to fabricate micro scale features like micro holes, micro channels, microgrooves and 3-dimensional intricate shapes on variety of materials. DC Voltage Bubbles <vnode Cathode Electrode tlectrode Electrolyte Single discharge radius |R) Glass workpiece
- 9. The important machining parameters of ECDM process are: • material removal rate. • depth of machining. • radial over-cut. • surface finish. • dimensional accuracy of the machined profile. Main Influencing parameters: • applied voltage. • electrolyte concentration. • area of tool cross-section dipped inside the electrolyte. • inter-electrode gap. Working Principle of ECDM: • The working principle in ECSM is by combination of thermal (LASER, Heat, Spark) and chemical energy.
- 10. ECDM Apparatus:
- 11. Ac to Dc converter:
- 12. Experimental setup of Electrochemical Discharge Machining process: chamber Exhaust System Control PC Machining Power Supplies • Exhaust system: Exhaust systems serve to fumes, toxic gases, obnoxious odours, heat and aerosols out of the process area. • Control system: Consists of micro-controller or servo operated subsystem to provide flexibility to tool or work piece. • Machining chamber: It is generally made of stainless steel to avoid of the corrosive action caused by electrolyte. • Power supply: Consisting of AC to DC converter and Voltage modulator or pulsed modulator.
- 14. Experimental setup of ECDM Generally, hydrogen (H2) gas bubbles are generated due to electrolysis process or electro-chemical reaction while electrical spark/discharge is produced between gaseous layer formed by gas bubbles and tool electrode (cathode) in the presence of electrolyte. Therefore, two phenomena, that is, hydrogen (H2) gas formation and discharge generation, cause material removal in ECSM. The material is removed due to simultaneous effect of melting, vaporization and chemical etching processes.
- 15. The common electrolytes used in this process are NaOH, NaNO3, NaCL, and KOH. The temperature of plasma channel is in the range of 800-20,000K. At this temperature, any non- conductive material is placed near the discharging zone with appropriate inter electrode gap (IEG) and then material removal takes place from workpiece surface due to melting and vaporization. Such phenomenon is known as material removal mechanism of ECSM process. Generally, IEG between tool-electrode and workpiece is in few micro-meters and depends on the machining conditions. The IEG between tool electrode and workpiece is 20mm or less than 25mm for machining of glass.
- 16. First practical experiment results:
- 17. Small Prototype of ECDM:
- 18. First result:
- 20. Final result microhole using ECDM:
- 21. Varients of Electrochemical Discharge Machining Process: Drilling-ECDM Sinkmg-ECDM Turmng-ECDM Grinding-ECDM Milling-ECDM TW-ECDM 1. Drilling ECDM 2. Sinking ECDM 3. Turning ECDM 4. Milling ECDM 5. Travelling Wire ECDM 6. Grinding ESDM
- 22. Advantages over ECM/EDM: • Better surface finishing. • Suitable for non-conducting materials. • High accuracy. • No chips or burrs formation. • Low power consumption. • Set-up is not costly and can be developed or fabricated on exciting facility through modification and attachments. Disadvantages over ECM,EDM: • Chances to electrode wear. • Initial cost of is high. • Thickness of ceramic material can be machined is limited to 1.5 mm. • Radial overcut.
- 23. Applications of ECDM ECDM is novel hybrid micro-machining technology for production of: • Through and blind micro-holes. • Micro-grooves. • Micro-slots. • Micro-channels and Complex shapes produced in non-conducting materials (quartz, glass, and ceramics) etc. • Miniature features of turbine blades (microturbulated cooling holes). • Filters for food and textiles industries. • Micro-electro seam welding for copper plate. • Industrial applications like bearings, computer parts, artificial joints, cutting tools, electrical and thermal insulators etc. • Trueing and Dressing of grinding wheels.
- 24. References: • Amitabha Ghosh "Electrochemical Discharge Machining: Principle and Possibilities" Sadhana Vol.22, Part 3, 1997,pp. 435- 447. @ Printed India. • Indrajit Basak, Amitabha Ghosh "Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification" Journal of Materials Processing Technology 71 (1997) 350-359. • Anjali V. Kulkarni "Electrochemical Discharge Machining Process" DEF SCI J, VOL. 57, NO.5, September2007. • Anjali. Kulkarni, R. Sharan, G.K. Lal "Experimental study of discharge mechanism in electrochemical discharge machining" International Journal. • S.K Hajra Choudhury, A.K Hajra Choudhury "Workshop technology" Volume:2 machine tools, Media promoters and publishers pvt. ltd. Thirteenth edition (2010) pp.605-650. • B. Doloi, B. Bhattacharyya and S.K. Sorkhel " Electrochemical Discharge Machining of Non-Conducting Ceramics " DEF SCI J, Vol49, No 4, August 1999, pp.331-338@1999, DESIDOC.