There is no contact between the tool and the work piece in this machining process hence it does not require expensive. The process of metal removal by electro chemical dissolution was known as long back as 1780 ad but it is only over the last couple of decades that this method has been used to advantage. Optimization of surface roughness in wire electrical discharge machining of titanium alloy siva prasad arikatla. Precision electrochemical machining pecm is a nonconventional machining process that can help deliver complex and precise components quickly and accurately. They have also tried to optimize mrr and r a prediction model using rsm. Large numbers of advanced machining processes are in existence today and few important among them are listed below. Journal of process mechanical engineering 2016 231. They have considered the three most important ecm process.
Electro chemical machining seems to be the future of micro and nanomachining due to its advantages like high mrr, no tool wear, highly precise, reliability, better control over machining and so on. Electrochemical machining is a nontraditional machining process which is used to. Control parameters optimization of laser beam machining. In any machining process optimization of process parameters is essential for achieving high rate of production with good quality, which is the preliminary basis for survival in todays dynamic market conditions. This paper is devoted to the study of micro ecm process to obtain a. The process is used in aerospace engineering and the automotive, construction, medical equipment, microsystem and. Optimization of electrochemical machining process parameters using.
Electrochemical micromachining ecmm is an emerging nonconventional technology for producing micromeso scale components 24. Chemical machining and ecm are thermalfree processes, but chemical machining cannot be applied to machine. Aim of the presentation give brief information about electro chemical machining process show the ecms working principles and tools define the advantages and disadvantages brief informations about application areas, economics, products and developments. Brar 10 experimented with the abrasive flow machining combined with simple ecm process i. Applications of optimization techniques for parametric. Investigation and optimization of process parameters in. Electrochemical machining ecm is a method of removing metal by an electrochemical process. Parameters optimization of advanced machining processes. It is also known as contactless electrochemical forming process. Electrochemical machining ecm is used to remove metal and alloys which are difficult or impossible to machine by. This paper attempts to establish a comprehensive mathematical model for correlating the interactive and higherorder. Chm applications range from large aluminum alloy airplane wing parts to minute integrated circuit chips. Optimization of process parameters of electrochemical. The shape of drill bit helical also affects the quality of surface.
Electrical discharge machining edm is a nonconventional machining process that is used for machining of hardtomachine materials, components in which length to diameter ratio is very high or products with a very complicated shape. In this paper, attempts have been made to model and optimize process parameters in abrasive assisted electrochemical machining aecm of aluminiumboron carbidegraphite composite using. Electrochemical machining ecm is a metalremoval process based on the principle of reverse electroplating. The performance of the chemical machining process is affected by several parameters, the more important of which. Electrochemical machining ecm is a nontraditional machining process uses the principle of faraday to remove metal from the workpiece. In this process, particles travel from the anodic material workpiece toward the cathodic material machining tool. Optimization of micro electrochemical machining of inconel. Electrochemical machining ecm give a better alternative in generating accurate three dimensional complex shaped components and components which are. In this paper, a particle swarm optimization algorithm is presented to find the optimal combination of process parameters for an electrochemical machining process. Optimization of electrochemical micro machining process using additive manufactured tool on titanium alloy ti3al2. It uses electrodes and a pulsed direct current to dissolve practically any electrically conductive metal, including highly tempered steel, rolling bearing steel and alloys. The subjects of the investigations are electrochemical machining using a closed electrolytic jet jetecm and highprecision electrochemical metal machining pecm. Electrochemical honing ech is a unique hybrid electrolytic precision microfinishing technology that combines electrochemical machining and conventional honing actions in a single operation to provide simultaneously controlled functional surfacegeneration and fast material removal capabilities.
Advanced processes include electrical and chemical means of material removal, as well as the use of abrasive jets, water. As both electrode and workpiece being electrically. Due to the complexity of electrochemical machining process it is very difficult to. Request pdf optimization of electrochemical machining process parameters using genetic algorithms ecm and ecmbased processes derived and hybrid processes are one of the most widely used. It is normally used for mass production and is used for working extremely hard materials or materials that are difficult to machine using conventional methods. Masking tape can be used to protect areas not to be removed. Electrochemical machining is a method that finishes the workpiece surfaces by means of anodic metal dissolution. Optimization of process parameters for electrochemical. This paper investigates the influence of the process parameters like machining voltage, electrolyte concentration, frequency on the over cut and material removal rate mrr through taguchi methodology and grey relational analysis. Ecm is used to machine workpieces through the anodic dissoultion of metal. Electrochemical discharge machining ecdm is a nontraditional machining process which combines the attributes of both electrochemical machining ecm and electrodischarge machining edm 1.
Optimization of process parameters on mrr and overcut in. Optimization study of electrochemical machining process. In chemical milling, shallow cavities are produced on plates, sheets, forgings and extrusions. This paper describes optimization of three most important ecm process parameters namely tool feed rate, electrolyte flow velocity, and applied. Considering these advantages of ga, optimization of nd. Pdf advanced machining processes are significant as higher accuracy in machined component is required in the manufacturing industries. The first step is to develop mathematical models to predict introduction. Electrochemical machining ecm is the generic term for a variety of electrochemical processes. Introduction electrochemical machining ecm is one of the newest and most useful nontraditional machining ntm process belonging to electrochemical category. Electrochemical machining of complex components of aeroengines. The machining parameters considered in the study are voltage, pulse on time, frequency, feed rate and pressure and the multiple responses are mrr and surface roughness r a. Electrochemical machining ecm could be used as one of the best nontraditional machining technique for machining electrically conducting, tough and difficult to machine material with appropriate machining parameters combination. A current of electrolyte fluid carries away the deplated material before it has a chance to reach the machining tool.
In this external circuit the flow of electron is from iron anode to. Optimization of machining parameters in electro chemical. Variables affecting the chemical machining of stainless. Electro chemical micro machining, taguchi method, process parameters, design of experiments. This nonelectrical process removes metal from selected or overall areas by controlled chemical action. Optimization of abrasive water jet machining process parameters using taguchi grey relational analysis.
Topsis method to optimize the electro chemical machining process parameters for titanium alloy ti 6 al 4 v. Jain et al 1 have proposed the optimization of electro chemical machining process parameters using genetic algorithms. The efficiency of products put a new demand for manufacturing. Other articles where chemical machining is discussed. Optimization of process parameters in edm for machining of. Optimization of process parameters of electrochemical machining hitesh dhiwar1, jitendra chauhan2 1,2department of mechanical engineering, india abstract in this thesis our work deals with the application of taguchi method to optimize the process parameters like machining voltage, electrolyte concentration, frequency will. Pdf optimization of electrochemical machining process based on. Optimization of electrochemical machining process parameters. Electrochemical machining ecm is a nonconventional machining process that is used for machining of hardtomachine materials.
The advantages include ability to machine very complex features in hard and difficult to machine materials with negligible tool. Pdf parameter optimization of electrochemical machining process. Experimental study on parametric optimization of titanium. Optimization of electrochemical machining process parameters using genetic algorithms, machining science and technology, 11, p.
Optimization of machine process parameters in edm for en. Optimization of process parameters in edm for machining of inconel 718 using response. In this paper, taguchi method is used to explore the effects of process parameters of electro chemical machining ecm viz. Yag laser beam machining process is done using this technique.
This paper discusses a methodology for the optimization of the machining parameters on drilling of al 6% gr metal matrix composites using electrochemical micro. Chemical machining chemical machining is a well known nontraditional machining process is the controlled chemical dissolution of the machined workpiece material by contact with a strong acidic or alkaline chemical reagent. Optimization of process parameters in electrochemical. Optimization of process parameters in electro chemical. Ecm can produce surface roughness of the order of 0. Ecmm electro chemical micro machining is one among such process, in which the material removal is happened due to the chemical energy 23. Pdf electrochemical machining ecm is one of nonconventional machining process used to operation the most harsh materials that difficult. However, it is very important to select optimum values of input process parameters to maximize the machining performance.
Electrochemical machining ecm, a nontraditional machining process offers a number of advantages. In this research work, the desired responses are minimum kerf taper and surface roughness. The objectives considered are dimensional accuracy, tool life, and the material removal rate subjected to the constraints of temperature, choking, and passivity. The purpose of this paper is to present a new method to optimize the electro chemical machining process parameters for titanium alloy ti6al4v. The method is related to the process used for making metal printing and engraving plates. Electrochemical machining ecm is one of the nonconventional machining. Combining response surface methodology and differential evolution algorithm ali mehrvar, ali basti, and ali jamali proceedings of the institution of mechanical engineers, part e. This paper investigates the effect and parametric optimization of process parameters for electrochemical machining of. Surface roughness is an important factor in electro chemical machining. This paper presents a taguchi loss functionbased hybrid strategy for the multi. The process control parameters considered are oxygen pressure, pulse width, pulse frequency and cutting speed.
Many problems such as higher surface roughness, heat affected zone and thermal stress are being happened while machining process such difficulttomachine. Electro chemical aided abrasive flow machining was possible with the help of polymeric electrolytes dabrowski et al. Influence of input parameters on characteristics of electro chemical machining process. Electrochemical machining ecm offers several unique feature, like higher machining rate, better surface finish, and it is suitable for machining a wide range of materials. Electrochemical machining process is a metal machining technology based on electrolysis where the product is processed without both contact with the tool and thermal influence. Utilization of particle swarm optimization technique for. These machining processes utilize electrical, chemical and optimal sources of energy to form and cut the materials. Optimization of surface roughness in wire electrical. Ecm can cut small or oddshaped angles, intricate contours or cavities in hard and. Multiobjective optimization of electrochemical machining of en31. Parameters optimization of advanced machining processes using tlbo algorithm advanced machining processes. Quality of machined surface strongly depend on the selection of optimal parameter settings and type of machining process.
Its use is limited to electrically conductive materials. Optimization of electrochemical micro machining process. Multiobjective optimization of electrochemical machining of. Optimization of process parameters for electrochemical machining of en19. Special coatings called maskants protect areas from which the metal is not to be removed. A hybrid approach for multiperformance optimization of. Optimization of surface roughness in electro chemical. Multiobjective optimization of electrochemical machining.
Optimization of machining parameters in electro chemical machin ing using response surface method maniraj. Multi performance optimization of electrochemical micro. Multicriteria optimization of surface roughness produced. This paper describes optimization of three most important ecm process parameters namely tool feed rate, electrolyte flow velocity, and applied voltage with an. Chemical machining is oldest of nontraditional machining processes employed as micromachining process to produce micronsize components.