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Investigation of process parameters on electrochemical micro machining of Cu-

Zn-Sn alloy

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 VOL. 12, NO. 21, NOVEMBER 2017 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
©2006-2017 Asian Research Publishing Network (ARPN). All rights reserved.

[Link]

INVESTIGATION OF PROCESS PARAMETERS ON ELECTROCHEMICAL

MICRO MACHINING OF Cu-Zn-Sn ALLOY
N. Jayakumar, R. Rajavel, A. [Link], P. Ramanathan and K. Srividhya
Department of Mechanical Engineering, AMET University, Chennai, India
E-Mail: jainanda2008@[Link]

ABSTRACT
Electrochemical micro machining (EMM) is one among the advanced manufacturing techniques to drill holes of
minute sizes, especially drilling holes with a diameter of below 1 mm. EMM offers quite a few advantages that include
superior machining rate, enhanced precision and control and a wider group of materials that can be machined. These are
pretty tough to accomplish through conventional machining process. In this investigation, parametric study of EMM was
conducted to congregate the requirements of proficient micromachining. Machining voltage, Electrolyte concentration, and
Pulse on time are the key process parameters that are significant for EMM. Performance of micro machining was observed
during material removal rate (MRR) and overcut. The outcome of this examination illustrated that machining voltage and
electrolyte concentrations are very important in affecting the performance characteristics.

Keywords: electrochemical micro machining (EMM), material removal rate (MRR), overcut.

INTRODUCTION electrochemical micromachining of stir-cast hybrid

EMM is being used frequently, these days, in the aluminium /(alumina + silicon carbide + carbon
micro machining of hard metals as excellent surface particulates) metal matrix composite. They developed an
quality could be achieved with hard surfaces such as EMM set-up and used it for conducting the experimental
ceramics and high alloy steels etc. When weighed up with investigation and selected supply current, supply voltage,
electrical discharge machining (EDM), electrochemical pulse-on time, pulse-off time, electrolyte concentration
machining (ECM) causes neither electrode wear nor heat- and electrolyte flow rate as process parameters. The
affected zone. Of late, several R&D activities have outcome of these parameters on MRR, electrode wear rate,
revealed that EMM is a potential technique with surface roughness height, taper cut, over cut and micro-
flexibilities in micro electromechanical systems (MEMS) spark-affected zone were evaluated by plotting graphs.
and in some advanced manufacturing domain. In The end result proved that the MRR, EWR, TC, OC and
comparison with contending technologies such as micro MSAZ increased with an increase in supply current,
EDM, ion beam machining and laser beam machining, voltage and pulse-on time. The most favorable parametric
EMM has plenty of benefits such as high removal rate, permutation for high MRR with low TC, OC, and MSAZ
very little or no wear in tool in the process, cost was found at 1.5 A supply current, 13 V supply voltage,
effectiveness and more importantly, it requires no special 10 µs pulse-on time, 10 µs pulse-off time, 15 g/L
equipments. EMM is one of among the most commonly electrolyte concentration, and 0.2 L/min electrolyte flow
followed manufacturing techniques in electronics industry, rate [2].
aviation industry, automobile industry and in medical field S. Dharmalingam et al. examined the power of
as well for a range of applications that include fabrication the process factors such as electrolyte concentration,
of metallic parts, PCBs, semiconductor devices, cooling machining voltage, frequency on the over cut and MRR by
holes in jet turbine blades and in surgical implants. Taguchi methodology and grey relational analysis. They
B. Mallick et al. studied diverse process discussed a method for optimizing the machining
constraints such as electrolyte concentrations, applied parameters on drilling of Al - 6% Gr Metal Matrix
voltage, pulse frequency and duty ratio on different composites using EMM. By investigation, most favorable
machining performance characteristics like MRR, overcut levels of parameters were found out and validated through
and HAZ during micro-profile making on electrically non- confirmation tests. The confirmation outcome proved that
conducting glass. They set the voltage, electrolyte there was reasonable improvement in MRR, Overcut and
concentration, pulse frequency and duty factor from 35-55 Grey relational grade. They were improved by 08.33%,
V, 10-30 wt%, 200Hz-1 kHz and 45-65% correspondingly 41.17% and 81.77% respectively. It was studied that the
for the period of his trialing. A cylindrical shaped stainless machining performance could be efficiently enhanced in
steel tool of diameter 350 μm was used and NaOH relation to initial parametric setting. [3]
solution was used as an electrolyte to conduct the Alakesh Manna and Anup Malik ventured an
experiments. It was found that material removal rate was attempt to discover the possibility to apply electrochemical
high for 55 V and 30 wt% electrolyte concentration machining technique to produce micro level drilled hole
respectively. Overcut and HAZ area decreased with on Al/10vol%Al2O3-MMC. They built up an EMM setup
frequency whereas they increased after 50% and 55% of and utilized it for experimental investigation and carried
duty ratio correspondingly [1]. out different experiments to explore the power of the
Charanjit Singh Kalra et al. made an EMM parameters on the material removal rate and radial
investigation on machining of micro-hole during overcut. Experimental end result illustrated that the

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 VOL. 12, NO. 21, NOVEMBER 2017 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
©2006-2017 Asian Research Publishing Network (ARPN). All rights reserved.

[Link]

machining voltage ranges from 5 to 10 volt would give a graphs to exhibit the influence of above said process
higher material removal when HCl is appended with NaCl parameters on MRR and over cut.
electrolyte. And the MRR increased with a rise in
machining voltage and concentration of NaCl electrolyte EFFECT OF MACHINING PARAMETERS ON MRR
[4].
[Link] et al. built up a second order, non- Effect of machining voltage on MRR
linear mathematical model for ascertaining the correlation Figure-2 reveals that the material removal rate
among different machining parameters, like applied rises with voltage at a certain machining parametric
voltage, electrolyte concentration and inter-electrode gap combination, i.e. an electrolyte (NaNO3) concentration of
with the principal machining process criteria, specifically 25 g/l and a pulse on time of 50 µs. It was also studied that
MRR, radial overcut and thickness of HAZ during an the MRR from 4 V to 5 V, 5 V to 6 V, 6 V to 7 V and
ECDM procedure on silicon nitride. They developed this from 7 V to 8 V are almost in similar pattern.
model depending on response surface methodology (RSM) This could be attributed to the clean machining
by using relevant experimental data, which were acquired atmosphere without any presence of contamination in the
during the ECDM micro-drilling operation on silicon electrolyte that prevailed during the micromachining.
nitride ceramics. They also offered an analysis of variance
(ANOVA) and a confirmation test to substantiate the
fitness and adequacy of the developed mathematical
models. From the parametric analyses based on
mathematical modeling, it was recommended that applied
voltage had more important consequences on MRR, ROC
and HAZ thickness during ECDM micro-drilling process,
comparing other machining parameters like electrolyte
concentration and inter-electrode gap [5].
In our endeavor, we are venturing into the
investigation of process parameters such as machining
voltage, electrolyte concentration and pulse on time on
EMM of 58.5% Cu-40% Zn-1.5% Sn alloy, especially on
Figure-2. MRR vs machining voltage (Electrolyte
MRR and over cut.
concentration: 25 g/l &pulse on time: 50 µs).
EXPERIMENTAL SETUP OF EMM
Effect of Electrolyte concentration on MRR
Figure-1 shows the trial set up of EMM in which
a Tungsten tool of 300μm diameter was used to perform
an end to end hole on a brass plate of 600μm thickness.

Figure-3. MRR vs Electrolyte concentration (Voltage: 7 V

&pulse on time: 50 µs).

From Figure-3, it was noted that the effect of

electrolyte concentration on MRR at a certain machining
parametric combination, i.e. a machining voltage of 7 V
and a pulse on time of 50 µs, is also identical to the graph
plotted with MRR Vs Machining voltage. Here the MRR
steadily rises with a rise in electrolyte concentration.
Figure-1. Electrochemical micro machine. The steady rise in MRR could be attributed to the
rise in machining current. The machining current increases
RESULTS AND DISCUSSIONS at higher electrolyte concentrations because of the bigger
Experiments were performed on the EMM set-up number of ions associated in the machining with higher
to envisage the influence of input machining voltage, electrolyte concentrations.
electrolyte concentration and pulse on time on MRR and
over cut. Investigational outcomes have been plotted on

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 VOL. 12, NO. 21, NOVEMBER 2017 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
©2006-2017 Asian Research Publishing Network (ARPN). All rights reserved.

[Link]

Effect of pulse on time on MRR This sparking causes unrestrained material

Figure-4 embodies the effect of Pulse on time on removal from the work piece and eventually ends up with
the MRR at a certain parametric combination i.e., an larger over cut. Hence, the over cut increases more
electrolyte concentration of 25 g/l and a machining voltage rapidly at higher voltages.
of 7 V. From the graph it is quite obvious that a rise in
pulse on time leads to a rise in MRR. Effect of Electrolyte concentration on over cut
Figure-6 illustrates the effect of electrolyte
concentration on over cut at a certain machining
parametric condition, i.e., a machining voltage of 7 V and
a pulse on time of 50 µs. As there is a rise in electrolyte
concentration, ions related with the machining operation in
the machining area is also on the rise. More
agglomeration of ions diminishes the reactions of
localization effect of electrochemical material removal.
This tends to witness higher over cut of the brass material
and thus reduces the machining accuracy.

Figure-4. MRR vs pulse on time (Electrolyte

concentration: 25 g/l, Voltage: 7 V).

Rise in pulse on time means that more time is

allowed for machining the work, because only during
pulse on time, the actual material removal takes place.
Hence, with the increase in pulse on time, average current
density increases and in turn, leads to the increase in
MRR.
Figure-6. Over cut vs Electrolyte concentration
EFFECT OF MACHINING PARAMETERS ON (Machining voltage: 7 V, Pulse on time: 50µs).
OVERCUT
Moreover, the comparatively larger
Effect of machining voltage on over cut agglomeration of electrolyte also leads to a rise in the
In order to measure machining accuracy, the over current density and in turn, results in bigger over cut. The
cut phenomenon has to be considered. It is evident from stray current effect increases because of the rise in
Figure-5 that over cut rises with the rise in machining machining voltage and the electrolyte concentration. Due
voltage. When the machining voltage increases, current to this fact, the contour of the drilled hole is almost
flux flow dips because of the localization effect. As there circular.
is less localization effect, the drifting current flow actually
increases in the micromachining zone and consequently it Effect of pulse on time on over cut
is affecting more material removal from the bigger area of Figure-7 proves that the over cut increases as
work piece that causes a rise in over cut. At voltages more pulse on time increases at a certain machining parametric
than 7 V, over cut phenomenon is more predominant as combination, i.e., a machining voltage of 7 V and an
electrochemical reactions produce H2 gas at micro-tool electrolyte concentration 25 g/l.
and the gas bubbles rupture down leading to the event of More the pulse on time, the average current
micro-sparking. would also be higher. For higher current, the localization
effect gets reduced and in turn, increases the over cut.

Figure-5. Over cut vs machining voltage (Electrolyte Figure-7. Over cut vs pulse on time (Machining voltage: 7
concentration: 25 g/l, pulse on time: 50µs). V, Electrolyte concentration: 25 g/l).

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 VOL. 12, NO. 21, NOVEMBER 2017 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
©2006-2017 Asian Research Publishing Network (ARPN). All rights reserved.

[Link]

CONCLUSIONS Optimization. Applied Mechanics and Materials 766-

This research work took up some key process 767:818-824.
parameters like Machining voltage, Electrolyte
concentration and Pulse on time and they have been [7] Dr. Dharmalingam. S, [Link], [Link] Raja
deemed to examine the influence on the MRR and over and Padmanaban Govindarajulu. 2015. Investigation
cut. A machining voltage range of 4 V to 8 V has given an
on Electrochemical Micro Machining of Al 6061-6%
considerable amount of MRR at modest accuracy. And the
most efficient region of pulse on time and electrolyte wt Gr based on Taguchi design of experiments.
concentration could be deemed as 20 µs to 60 µs and 10 International Journal of Chem Tech Research. 7(1):
g/l to 30 g/l respectively. These parametric conditions 203-211.
have given us an appreciable quantity of MRR and over
cut. From the graphs, it could be inferred that a lower [8] Introduction to micromachining, [Link] (editor)
value of electrolyte concentration with higher machining published by Narosa publishers, New Delhi (2009).
voltage and modest value of pulse on time will generate (Second Edition).
less over cut at modest MRR for electrochemical
micromachining of brass.

REFERENCES

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[2] Charanjit Singh Kalra, Vinod Kumar and Alakesh

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[3] Dharmalingam, [Link], [Link], [Link]

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