Investigation on electrochemical machining(ECM) for optimization of surface roughness using response surface methodolgy(RSM)

Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear. This thesis is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).By using RSM method this thesis highlight features of the development of a comprehensive mathematical model for correlating the interactive and higher-order influences of various machining parameters on the dominant machining criteria, i.e. the surface roughness. Optimal combination of these two parameters is used in order to achieve minimisation of surface roughness for optimal accuracy of shape features. In the experiment, mild steel is used as specimen. Based on the Experimental result using RSM it is shown that minimum value of surface roughness can be obtained at the optimal combination of two parameters

Advances in Micro and Nano Manufacturing: Process Modeling and Applications

Micro- and nanomanufacturing technologies have been researched and developed in the industrial environment with the goal of supporting product miniaturization and the integration of new functionalities. The technological development of new materials and processing methods needs to be supported by predictive models which can simulate the interactions between materials, process states, and product properties. In comparison with the conventional manufacturing scale, micro- and nanoscale technologies require the study of different mechanical, thermal, and fluid dynamics, phenomena which need to be assessed and modeled.This Special Issue is dedicated to advances in the modeling of micro- and nanomanufacturing processes. The development of new models, validation of state-of-the-art modeling strategies, and approaches to material model calibration are presented. The goal is to provide state-of-the-art examples of the use of modeling and simulation in micro- and nanomanufacturing processes, promoting the diffusion and development of these technologies

Optimization and Experimental Investigation on EN19 Using Hexagonal Shaped Electrode in ECM

Electrochemical machining (ECM) has inaugurated itself as one of the major other possible way to conventional methods for machining hard materials and complicated outlines not having the residual stresses and tool wear. Electrochemical machining has vast application in automotive, Aircraft, petroleum, aerospace, textile, medical and electronic industries. Studies on Material Removal Rate (MRR) are of extremely important in ECM, since it is one of the factors to be Determined in the process decisions. So the aim of present work is to investigate the metal removal rate, over-cut diameter and surface roughness of EN19 alloy steel of diameter 13cm as work piece by using hexagonal shaped Brass electrode and brine solution as electrolyte by using Taguchi approach, then optimizing to find best setting of process variables for higher MRR, lower surface roughness and over-cut. Three parameters were chosen as process variables are: voltage, tool Feed rate and Electrolyte concentration. Result shows that 1) Among 3 factors feed rate is effecting MRR most then comes voltage and at last electrolyte concentration. 2) For surface roughness, feed rate effects it most then concentration and at last voltage. 3) Tool feed rate effects most to over cut at second rank is voltage and at third rank is concentration which affects most to over-cut. 4) In optimizing the quality loss function, it is found that experiment run no 5 is most optimal i.e. voltage=10V, tool feed rate= 0.4 mm/min and electrolyte concentration =22.03g/l for maximizing MRR and minimizing both over-cut and surface roughness

Multi Response optimization of characteristics of AISI D2 steel using utility concept and harmonic search method machined with different tool materials

Electrochemical machining (ECM) is widely used in manufacturing industry due to its many superior properties like no tool wear, good surface finish. Any conducting material can be machined with high dimensional accuracy and intricate designs can be easily carved on difficult to machine materials irrespective of their hardness. The magnetic properties and hardness etc. of the substrate material remain unchanged after machining with ECM due to lesser temperature generation during machining. The main challenge for using this method is that the specific energy requirement for the process is very large (about 150 times that required for conventional processes). Hence optimization techniques are necessary to get the best set of parameters in order to enhance the quality of machining. In the present work AISI D2 steel is machined with three different types of tools, copper, brass and graphite. Comparative study of the output responses obtained by machining with different tools was done to examine the advantage provided by individual tool material on the performance characteristics. Design of experiments was carried out using Response surface methodology combined with utility concept to convert the multi response system into an equivalent single response objective function by giving equal weightage to all the responses. Finally the responses were optimized by the nature inspired optimization technique Harmonic search algorithm as it takes lesser time and fewer calculations to optimize the responses. It was found that graphite tool gives the highest value of MRR and lowest value of overcut as compared to copper and brass tool while surface roughness obtained by machining with brass tool was found to be minimum