International Journal of Applied Science and Engineering
Published by Chaoyang University of Technology

C. Senthilkumara*, G. Ganesana, and R. Karthikeyanb

aDepartment of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamilnadu, India
bDepartment of Mechanical Engineering, BITS, Dubai


 

Download Citation: |
Download PDF


ABSTRACT


Proper selection of manufacturing conditions is one of the most important aspects in the die sinking Electrochemical Machining process, as these conditions determine important characteristics such as Material Removal Rate and Surface Roughness. The material used in the study was LM25Al/10%SiCp composite. Experiments have been carried out to establish an empirical relationship between process parameters and responses in ECM process using Response Surface Methodology. The developed empirical relationships predict the machining conditions within the experimental domain. Analysis of variance (ANOVA) is employed to indicate the level of significance of machining parameters. The contour plots are generated to study the effect of process parameters as well as their interactions. MRR is influenced by applied voltage and tool feed rather than other parameters. Electrolyte concentration has most significant factor on Ra rather than other parameters.


Keywords: Electrochemical machining (ECM); response surface methodology (RSM); metal removal rate (MRR); surface roughness (Ra).


Share this article with your colleagues

 


REFERENCES


 

[1] Zhu, D., Xu, Z., Xu, Q., and Liu, J. 2010. Investigation on the flow field of W-shape electrolyte flow mode in electrochemical machining. Journal of applied chemistry, 40: 525-32.

[2] Neto, J. C. D. S., Silva, E. M. D., and Silva, M. B. D. 2006. Intervening Variables in electrochemical machining. Journal of Material Processing Technology, 179: 92-96.

[3] Asokan, P., Ravi, Kumar, R., Jeyapaul, R., amd Santhi, M. 2008. Development of multi-objective optimization models for electrochemical machining process. International Journal of Advanced Manufacturing Technology, 39: 55-3.

[4] Ding, X., Liew, W. Y. H., and Liu, X. D. 2005. Evaluation of machining performance of MMC with PCBN and PCD tools. Wear, 259, 7-12: 1225-34.

[5] Liu, J. W., Yue, T. M., and Guo, Z. N. 2009. Wire electrochemical discharge machining of Al2O3 particle reinforced Aluminum Alloy 6061. Material Manufacturing Process, 24: 446-53.

[6] Kansal, H. K., Sehijpa, S., and Kumar, P. 2005. Parametric optimization of powder mixed electrical discharge machining by response surface methodology. Journal of Material Processing Technology, 169: 427-436.

[7] Kanagarajan, D., Karthikeyan, R., and Palanikumar, K. 2007. Parametric optimization of electro discharge machining characteristics of WC/Co composites by response surface methodology. Journal of Engineering Manufacture, 222: 807-815.

[8] Montgomery, D. C. 1997.“Design and Analysis of Experiments. fourth ed., Wiley, New York.

[9] Chiang, K. T., Chang, F. P., and Tsai, D. C. 2007. Modeling and analysis of the rapidly resolidified layer of SG cast iron in the EDM process through the response surface methodology. Journal of Material Processing Technology, 182: 525-533.

[10] Kuppan, P., Rajadurai, A., and Narayanan, S. 2006. Experimental investigation into electrical discharge deep hole drilling of Inconel 718 using graphite electrode. in:Proceedings of the 17th All India machine tool design and research conference, Roorke, Delhi, 923-927.   

[11] Sarkar, B. R., Doloi, B., and Bhattacharyya, B. 2006. Parametric analysis on electrochemical discharge machining of silicon nitride ceramics. International Journal of Machine Tools Manufacture, 28, 9-10: 873-81.

[12] Sen, M. and Shan, H. S. 2005. Analysis of hole quality characteristics in the electro jet drilling process. International Journal of Machine Tools Manufacture, 45:137-52.

[13] El-Taweel, T. A. 2008. Modelling and analysis of hybrid electrochemical turning magnetic abrasive finishing of 6061 Al/Al2O3 composite. International Journal of Advanced Manufacturing Technology, 37: 705-14.

[14] Pa, P. S. 2008. Design of effective plate-shape electrode in ultrasonic electrochemical finishing. International Journal of Advanced Manufacturing Technology, 34, 1-2: 70-8.


ARTICLE INFORMATION


Received: 2012-03-03
Revised: 2012-04-28
Accepted: 2012-05-22
Available Online: 2013-03-01


Cite this article:

Senthilkumar, C., Ganesan, G., Karthikeyan, R. 2013. Influence of input parameters on characteristics of electro chemical machining process. International Journal of Applied Science and Engineering, 11, 13–24. https://doi.org/10.6703/IJASE.2013.11(1).13