Investigations on Machining of Monel 400 Alloys Using Electrochemical Machining with Sodium Nitrate as Electrolyte

2014 ◽  
Vol 592-594 ◽  
pp. 467-472 ◽  
Author(s):  
M. Kalaimathi ◽  
G. Venkatachalam ◽  
Neil Pradeep Makhijani ◽  
Ankit Agrawal ◽  
M. Sivakumar
Keyword(s):  
Process Parameters ◽  
Sodium Nitrate ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Research Field ◽  
Electrode Gap ◽  
Conventional Machine ◽  
Monel 400 ◽  
Physical And Chemical ◽  
The Impact

Monel 400 is a cuprous nickel alloy which is very well-known for its resistivity towards physical and chemical strength. It is probably one of the hardest and most non-corrosive materials known in industrial as well as research field. These properties have enhanced its applications in various fields such as aerospace industries, marine industries, automotive industries etc. Monel 400 alloys are too hard to machine using conventional machine tools and methods as it work hardens rapidly on its surface. Authors concluded that electrochemical machining is the choice of machining of these materials. The present work is carried out to analyze the impact of ECM process parameters such as applied voltage (V), inter-electrode gap (IEG) and electrolyte concentration (EC) on material removal rate (MRR) and surface roughness (Ra). An aqueous sodium nitrate (NaNO3) is used as basic electrolyte in the electrochemical machining of Monel 400 alloys. Response surface methodology (RSM) based central composite design (CCD) is used as experimental strategy. Effects of process parameters as well as their interactions are analysed and the process parameters are optimized.

scholarly journals Optimization of Process Parameters During Electrochemical Machining

2019 ◽  
Vol 8 (12) ◽  
pp. 2683-2687
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Research Work ◽  
Electrochemical Machining ◽  
Machining Processes ◽  
Electrode Gap ◽  
Optimization Of Process Parameters ◽  
Finishing Process ◽  
Nimonic 80A ◽  
The Right

Electrochemical machining is one of the most efficient machining processes due to its ability to produce completely stress-free machined components without any need of further finishing process. However, the right understanding of the effects of key factors during machining of various materials is very important to carry out the machining. It is one of the most efficient way of cutting present in modern era. This present paper deals with the electrochemical machining of Nimonic 80A. Design of the experiments are done by using response surface methodology to study the material removal rate and surface roughness. Process parameters such as voltage, tool feed rate, inter-electrode gap and electrolyte concentration has been optimized by using the ANOVA. The regression models are developed to be used as predictive tools. The confirmation test was conducted to validate the results achieved by GRA approach. This research work helps the industrialist for selecting parameters to attain desired outputs.

scholarly journals The effects of the process parameters in electrochemical machining on the surface quality

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Nguyen Thi Bich Nhung ◽  
Dao Thanh Liem ◽  
Truong Quoc Thanh
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Electrode Gap

Based on the number of previous studies, this study aims to investigate the effects of process parameters of an Electrochemical Machining process, which are electrolyte concentration, the voltage applied to the machine, feed rate of the electrode, and Inter-Electrode Gap between tool and workpiece. Aluminum samples of 25 mm diameter x 25 mm height and 30mm diameter x 25mm height of the tool is made up of copper with a circular cross-section with 2 mm internal hole. The design of the system is based on the Taguchi method. Here, the signal-to-noise (S/N) model, the analysis of variance (ANOVA) and regression analyses are applied to determine optimal levels and to investigate the effects of these parameters on surface quality. Finally, the experiments that use the optimal levels of machining parameters are conducted to verify the effects of the process parameters on the surface quality of the products. The results pointed out a set of optimal parameters of the ECM process. The Inter-Electrode Gap between the tool and workpiece has extremely effected on these Material Removal rates and surface roughness. The Material Removal Rate increases with diseases in Inter-Electrode Gap, and Ra diseases with diseases in Inter-Electrode Gap. The experimental results show that maximum Material Removal Rate has obtained with electrolyte concentration at 100 g/l, feed rate at 0.0375 mm/min, the voltage at 15V, and Inter-Electrode Gap at 0.5mm. The minimum Ra has obtained with electrolyte concentration at 80 g/l, feed rate at 0.0468 mm/min, the voltage at 10V, and Inter-Electrode Gap at 0.5mm. This result has led to need studies on these parameters in Electrochemical Machining, which are improving productivities and surface roughness of the products.   

Effect of Process Parameters on MRR and Surface Roughness in ECM of EN 31 Tool Steel Using WPCA

2017 ◽  
Vol 4 (2) ◽  
pp. 45-63 ◽  
Author(s):  
Milan Kumar Das ◽  
Tapan Kumar Barman ◽  
Kaushik Kumar ◽  
Prasanta Sahoo
Keyword(s):  
Surface Roughness ◽  
Tool Steel ◽  
Process Parameters ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Parameters ◽  
Electrode Gap ◽  
En 31 ◽  
Taguchi Orthogonal Design

Weighted principal component analysis is used to predict the optimal machining parameters for EN 31 tool steel in electrochemical machining for minimum surface roughness and maximum material removal rate based on L27 Taguchi orthogonal design. For this, multi-response performance index is calculated to derive an equivalent single objective function and then Taguchi method is used to optimize the process parameters. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). Results show that the main significant factor on MRR and surface roughness is electrolyte concentration. The effects of process parameters viz. electrolyte concentration, voltage, feed rate and inter-electrode gap on MRR and surface roughness are also investigated using 3D surface and contour plots. Finally, the surface morphology is studied with the help of scanning electron microscopy (SEM) images.

Optimization of Process Parameters for Electro-Chemical Machining of EN19

2019 ◽  
pp. 127-142 ◽  
Author(s):  
Divya Zindani ◽  
Nadeem Faisal ◽  
Kaushik Kumar
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Input Parameter ◽  
Electrochemical Machining ◽  
Pso Algorithm ◽  
Machining Process ◽  
Matrix Composites ◽  
Machining Performance ◽  
Electrode Gap ◽  
Optimization Of Process Parameters

Electrochemical machining (ECM) is a non-conventional machining process that is used for machining of hard-to-machine materials. The ECM process is widely used for the machining of metal matrix composites. However, it is very essential to select optimum values of input process parameters to maximize the machining performance. However, the optimization of the output process parameters and hence the machining performance is a difficult task. In this chapter an attempt has been made to carry out single and multiple optimization of the material removal rate (MRR) and the surface roughness (SR) for the ECM process of EN19 using the particle swarm optimization (PSO) technique. The input parameter considered for the optimization are electrolyte concentration (%), voltage (V), feed rate (mm/min), and inter-electrode gap (mm). The optimum value of MRR and SR as found using the PSO algorithm are 0.1847 cm3/min and 25.0612, respectively.

Friction Behavior of CMP Slurries Based on Novel Organic Particles

2005 ◽  
Author(s):  
Yuzhuo Li ◽  
Ning Wang
Keyword(s):  
Removal Rate ◽  
Dielectric Materials ◽  
Friction Behavior ◽  
Abrasive Particles ◽  
Added Benefit ◽  
Increasing Demand ◽  
Organic Particles ◽  
Physical And Chemical ◽  
The Impact ◽  
First Time

With the integration of copper as interconnect and low k materials as dielectric, the CMP community is facing an ever increasing demand on reducing defectivity without scarifying production throughput. One such strategy is to significantly lower the polishing pressure to below 1 psi. Such a move has placed tremendous challenges to the tool manufactures, consumable suppliers (especially the slurry vendors), and end-users. It is a challenge to remain the high throughput (MRR and selectivity) at low down force without using harsh abrasives. For the first time, we recently report the use of novel hydrophilic organic particles for metal CMP. Unlike conventional abrasive particles such silica or alumina, these unique particles are designed to specifically interact with the metal surface to be polished and significantly modify the rheological behavior of the slurry. The obvious advantage of using such particles is the reduction of defects during CMP. The consequence of using such particles is also its ability to provide unsurpassed high selectivity in removal rate for copper over barrier and dielectric materials due to their weak interaction with these particles. The added benefit for slurry that uses such particles is to allow CMP process conducted at a lower down force without compromising the throughput. In this talk, some basic physical and chemical characteristics of the particles and slurry will be first presented. The friction beavior of these new slurries in relation to conventional slurries on blanket wafers will be discussed. The impact of particle hydrophobicity on the friction behviors of the slurries will be explored.

Abrasive Assisted Electrochemical Machining of Al-B4C Nanocomposite

2015 ◽  
Vol 787 ◽  
pp. 523-527 ◽  
Author(s):  
K. Rajkumar ◽  
L. Poovazhgan ◽  
P. Saravanamuthukumar ◽  
S. Javed Syed Ibrahim ◽  
S. Santosh
Keyword(s):  
Particle Size ◽  
Boron Carbide ◽  
Process Parameters ◽  
Positive Impact ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Weight Ratio ◽  
High Strength ◽  
High Wear Resistance ◽  
Particle Size Reduction

Aluminium reinforced with SiC, Al2O3 and B4C etc. possesses an attractive combination of properties such as high wear resistance, high strength to weight ratio and high specific stiffness. Among the various reinforced materials used for aluminium, B4C has outperformed all others in terms of hardening effect. Particle size reduction of B4C is found to have positive impact on the material hardness. In the view of physical properties, B4C has less density than that of SiC and Al2O3, which makes it an attractive reinforcement for aluminium and its alloys for light weight applications. In this work, Al nano B4C composite prepared by ultrasonic cavitation method was machined by Abrasive assisted electrochemical machining using cylindrical copper tool electrodes with SiC abrasive medium. In this paper, attempts have been made to model and optimize process parameters in Abrasive assisted Electro-Chemical Machining of Aluminium-Boron carbide nano composite. Optimization of process parameters is based on the statistical techniques using Response Surface Methodology with four independent input parameters such as voltage, current, abrasive concentration and feed rate were used to assess the process performance in terms of material removal rate and surface finish. The obtained results were compared with abrasive assisted electro chemical machining of Aluminium-Boron carbide micro composite and the effect of particle size on the process parameters was analyzed.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

scholarly journals The Mass Transfer Intensification of Combined Treatment Products

2019 ◽  
Vol 297 ◽  
pp. 01002
Author(s):  
Oleg Skrygin ◽  
Vladislav Smolentsev ◽  
Anton Schednov
Keyword(s):  
Mass Transfer ◽  
Removal Rate ◽  
Hydrodynamic Instability ◽  
Combined Treatment ◽  
Geometrical Shape ◽  
Electrode Gap ◽  
Electrode Tool ◽  
Working Media ◽  
The Impact ◽  
Mass Transfer Intensification

The paper addresses the issues, related to mass transfer of treatment products when using combined forming methods with the application of an electric field. The impact of process components upon strength characteristics of parts has been shown. We have discovered the dependence of allowance removal rate upon the quality of preparation of the reference workpiece surface. The article describes the available industrial and newly developed methods of mass transfer intensification, using the original kinematics of movement, the improvement of the geometrical shape, the position of electrode-tools and the application of various options in the flow of liquid working media, including the cavitational mode, described in detail for the first time. We have disclosed the mechanism of the impulse effect upon treatment products, ejected from the inter-electrode gap by the liquid working medium. The issues have been discussed, concerning the hydrodynamic instability of liquid working media flow, impacting the intensity of mass transfer, with limitations, caused by the impact of side surfaces of holes and channels when processing with a profiled and a non-profiled wire electrode-tool. We have shown the impact of a concentrated ultrasonic beam upon mass transfer of treatment products, formed at a great distance from the electrode.

An Investigation of Factors Affecting and Optimizing Material Removal Rate in Computer Controlled Ultra-Precision Polishing

2014 ◽  
Vol 625 ◽  
pp. 446-452
Author(s):  
Lai Ting Ho ◽  
Chi Fai Cheung ◽  
Liam Blunt ◽  
Sheng Yue Zeng
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Orthopedic Implants ◽  
Polishing Process ◽  
Factors Affecting ◽  
Ultra Precision ◽  
Computer Controlled ◽  
The Impact

There are numerous parameters and steps involved in a computer controlled ultra-precision polishing process (CCUP). The success of CCUP relies heavily on the understanding and optimization of material removal when new materials and new surfaces are polished. It is crucial to optimize the polishing parameters to enhance the effectiveness of the polishing process and to assess the impact of different process parameters on the material removal rate of particular difficult-to-machine materials such as CoCr alloys, which is commonly used in orthopedic implants. This paper aims at studying the process parameters and optimization of the parameter to enhance the material removal rate and quantify the contribution of process parameters.

Electrochemical machining of 20MnCr5 alloy steel with magnetic flux assisted vibrating tool

2015 ◽  
Vol 231 (10) ◽  
pp. 1956-1965 ◽  
Author(s):  
S Ayyappan ◽  
K Sivakumar ◽  
M Kalaimathi
Keyword(s):  
Magnetic Flux ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Low Frequency ◽  
Full Potential ◽  
Hybrid Technique ◽  
Machining Performance ◽  
Electrode Gap ◽  
Contour Plots ◽  
Control Of Parameters

Utilization of full potential of electrochemical machining (ECM) is not yet achieved because of its lack of accuracy, difficulty in proper tool design and control of parameters. The enhancement of performance of ECM is still a subject of concern in this modern manufacturing world. In this work, low frequency vibrating tool assisted by a magnetic flux was used as an efficient hybrid technique in ECM for improving material removal rate (MRR) and surface roughness (Ra). This paper presents a development of mathematical model correlating MRR and Ra with machining conditions such as voltage, electrolyte concentration, and inter-electrode gap. The significance of ECM process parameters has been investigated using contour plots. The inter-electrode gap (IEG) is considered slightly higher than the maximum tool amplitude that otherwise leads to tool damage. Results indicate that magnetic flux-assisted vibrating tool increases the MRR from 10% to 96%. A magnetic flux-assisted vibrating tool in ECM facilitates and drives out the sludge in the IEG to improve the machining performance. MRR is enhanced due to the movement of ions triggered by magnetic flux, which assures an increase in anodic current. A slight increase in Ra was also noted in comparison to machining with aqueous NaCl electrolyte alone.

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