A COMPARATIVE STUDY FOR SELECTION OF EFFECTIVE ELECTROLYTE SOLUTION FOR ELECTROCHEMICAL DISCHARGE MACHINING

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1 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND TECHNOLOGY (IJMET) International Journal of Mechanical Engineering and Technology (IJMET), ISSN (Print), ISSN (Print) ISSN (Online) Volume 6, Issue 1, January (2015), pp IAEME: Journal Impact Factor (2015): (Calculated by GISI) IJMET I A E M E A COMPARATIVE STUDY FOR SELECTION OF EFFECTIVE ELECTROLYTE SOLUTION FOR ELECTROCHEMICAL DISCHARGE MACHINING M.L.Harugade 1, N.V.Hargude 2, A P Shrotri 3, S.P.Shinde 4 1 Assistant Prof. Dept. of Mechanical Engg, PVPIT, Budhgaon , M.S.India 2 Associate Prof. Dept. of Mechanical Engg, PVPIT, Budhgaon , M.S.India 3 Associate Prof. Dept. of Mechanical Engg, PVPIT, Budhgaon , M.S.India 4 Assistant Prof. Dept. of Mechanical Engg, PVPIT, Budhgaon , M.S.India ABSTRACT Electrochemical discharge machining ECDM is an advanced hybrid machining process which can be successfully used for machining electrically non-conductive materials such as glass ceramics and composites materials which are now a day s used extensively for engineering applications. It is combination of ECM and EDM. The performance of the process is highly nonlinear and complex depends upon number of parameters associated with physical and chemical partners of the process. However the performance largely depends on type and concentration of electrolyte solution used. The electrolyte also governs the wear of electrode and MRR of the process. This paper highlights on such facts associated with the electrolyte used and its impact on the process of ECDM. Keywords: ECDM, Electrolyte Solution, Sparking, Spark Colour 1. INTRODUCTION The electrochemical discharge machining (ECDM) process is a thermal chemical machining system; ECDM is advanced hybrid machining process combination of electrochemical machining (ECM) and electro discharge machining (EDM).It can be successfully used for machining electrically non-conductive advanced engineering materials such as glass, composite and ceramics materials. The performance of ECDM, in terms of material removal rate, tool wear rate and radial over cut, is affected by many factors such as electrolyte solution, electrolyte concentration and inter- 98

2 electrode gap. Relationships between these factors and machining performance are highly non-linear and complex in nature. But by many research works it has been found that electrolyte 2. PRINCIPLE OF ECDM Fig 2.1: Principle of ECDM process The electrochemical discharge phenomenon is clearly demonstrated by the above simple figure. Two electrodes are dipped inside an aqueous electrolyte. The cathode is chosen with a much smaller surface than the anode. When the D.C. voltage is applied electrolysis happens and Hydrogen gas bubbles are formed at the tool-electrode (cathode) and oxygen bubbles at the counter electrode (anode). When the voltage is increased, the current density increases too and more and more bubbles grow forming a bubble layer around the electrodes. When the voltage is increased above the critical voltage, bubbles coalesce into a gas film around the tool-electrode. Sparking phenomena is observed in the film where electrical discharges happen between the tool-electrode and the surrounding electrolyte. Similar behavior can be obtained by inverting the polarity of the electrodes and by changing the electrolytes. Fig 2.1 explains the ECDM phenomenon [5] [8][9]. 99

3 3. COMPARATIVE STUDY BETWEEN VARIOUS ELECTROLYTE SOLUTIONS AND MACHINING PARAMETERS Table 3.1: Comparative study between electrolyte solutions and machining parameters [4] [10] [11] [12] Sr. No Existing machining parameters for various electrolyte solution 1. W/p. material - Soda lime glass 2.Electrolyte solution H 2 SO 4 1.W/p. material Zirconium oxide 2. Electrolyte solution - KOH 1. W/p. material Silicate nitrate ceramic(si 3 N 4 ) 2. Electrolyte solution - NaOH 1. W/p. material - Glass-epoxy composites 2. Electrolyte solution - NaCl Voltage- 60V Conc.- 30% Inter-electrode gap- 10mm Voltage - 50V Conc.- 25% Inter-electrode gap- 20mm Voltage - 70V Conc.- 18% Inter-electrode gap- 27mm Voltage- 75V Conc.- 20% Inter-electrode gap- 50mm 3.1Classification of electrolyte [13] Many researchers show that KOH and NaOH are suitable for constant sparking, KOH and NaOH has strong base. Also some researchers used H 2 SO 4, NaCl, NaNO 3, in this H 2 SO 4 is strong acid. NaCl and NaNO 3 are salts of strong acid strong base. Electrolyte Acid Salt Ex. H 2 SO 4 Ex. NaOH KOH Ex. NaCl NaNO 3 For ECDM, electrolyte solution may acid, salt or base but it should be strong. Because for maximum sparking and bubble formation electrolyte should be a good electric conductor, which is as in the case of strong solutions. 100

4 3.2 Properties of electrolyte Molecular formula KOH NaOH NaCl NaNO 3 Molar mass g/mol Table 3.2: Properties of electrolyte [13] Appearance Odour g/mol White solid Odourless g mol g mol g/mol H 2 SO g/mol Opaque crystals, White Colorless crystals Colorless crystals Clear, colorless Odourless Odourless Sweet Odourless Density g/cm Melting point O C Boiling point O C g/cm 406 C 1327 C 2.13 g/cm C 1388 C 4. EFFECT OF ELECTROLYTE SOLUTION ON WORK-PIECE MATERIAL Solubility 121 g/100 ml (at 25 C) 111 g/100 ml (at 20 C) g cm C 1413 C 359 g l g/100 g/cm 3, ml 308 C 380 C solid (at 25 C) 1.84 g/cm 3, liquid 10 C 337 C miscible 4.1 Effect of electrolyte concentration on material removal rate Previous authors have proposed effect of electrolyte concentration over material removal rate by finite element method. It was observed that with increase in electrolyte concentration from 10% to 30%, material removal rate increased significantly especially in soda lime glass and thereafter the concentration does not play any role to enhance the MRR. This can be explained from the fact that as the concentration is increased, the critical voltage and critical current increases. An increase in electrolyte current would mean the accelerated electrolysis process. It would result in greater rate of hydrogen bubbles at the cathode tool. The increased rate of hydrogen bubbles at the cathode implies an enhanced rate of sparking and hence higher MRR. [1] [4] [5] The surface texture obtained is dependent on the concentration of the electrolyte used, i.e., its viscosity. For high electrolyte concentrations, however, cracks may form on the machining surface. [2] 4.2 Effect of electrolyte temperature on material removal rate When electrolyte temperature increases electrolyte conductivity increases too, thus increasing the amount of current which accelerates the electrolysis process, resulting in a greater rate of evolution of hydrogen gas bubbles at the cathode. The increased rate of formation of gas bubbles at the cathode leads to an enhanced rate of sparking, hence higher material removal. So it can be said that material removal increases with the increased conductivity. [6] [7] 5. RELATIONSHIP BETWEEN COLOUR OF THE SPARK AND ELECTROLYTE SOLUTION In this research it is seen that electrolyte solution has effect on colour of the spark. Colour of the spark changes with electrolyte solution it can be seen from photos below that colour of spark can change according to electrolyte solution used. 101

5 Electrolyte Solution KOH Electrolyte Solution NaCl Electrolyte Solution H 2 SO 4 First photo bright yellow spark stable and constant, in this process KOH is used as electrolyte solution. In second photo NaCl is used as electrolyte in which melting of auxiliary electrode can be seen, in this process tool electrode wear rate is more. Third photo H 2 SO 4 electrolyte solution is used in which it shows that the colour of spark is blue. In this process sparking fluctuate continuously which increases chances of glass break by 30%. 6. CONCLUSION Electrochemical discharge machining ECDM is an advanced hybrid machining process which can be successfully used for machining electrically non-conductive materials. The performance of the process is highly non-linear and complex depends upon number of parameters associated with physical and chemical partners of the process. It is by and large governed by the electrolyte solution used and its concentration. The comparative study highlighted in this paper indicate the fact that the nature and colour of spark largely depends on type and concentration of electrolyte used and it also shows variation in the process output. The acidic electrolyte solution shows intermittent and disturbed spark which result in excessive erosion of electrode and damage to the work-piece. The salty electrolyte solution shows remarkable wear of tool however no damage to work-piece is recorded. The basic electrolyte solution shows negligible wear, constant spark and better surface finish of work-piece. With these observation it can concluded that use of basic electrolyte solution. Leads to better performance of ECDM process. 7. REFERENCES 1. K.L. Bhondwe, Vinod Yadava, G. Kathiresan, Finite element prediction of material removal rate due to electro-chemical spark machining International Journal of Machine Tools & Manufacture, vol.46 (2006), pp Jana D. Abou Ziki, Tohid Fatanat Didar, Rolf Wuthrich, Micro-texturing channel surfaces on glass with spark assisted chemical engraving International al Journal of Machine Tools & Manufacture vol.57 (2012), pp Chih-Ping Chenga, Kun- LingWub,n, Chao-ChuangMai a, Cheng-KuangYang c, Yu-Shan Hsu c, Biing- HwaYan, Study of gas film quality in electrochemical discharge machining International Journal of Machine Tools & Manufacture,vol.50 (2010), pp

6 4. V. K. Jain, P. Sreenivasa Rao, S. K. Choudhary, K. P. Rajurkar Experimental Investigations into Traveling Wire Electrochemical Spark Machining (TW-ECSM) of Composites Journal of Engineering for Industry, Vol.113 (1991), pp R. Wuthricha, V. Fasciob, Machining of non-conducting materials using electrochemical discharge phenomenon An overview International Journal of Machine Tools & Manufacture, vol.45 (2005), pp A Kulkarni R. Sharan G.K. Lal, Measurement of Temperature Transients in Electrochemical Discharge Machining Process. Indian Institute of Technology, Kanpur , INDIA. 7. V.K. Jain, S.K. Choudhury, K.M. Ramesh, On the machining of alumina and glass International Journal of Machine Tools & Manufacture, vol.42 (2002), pp Sanjay K. Chak, P. Venkateswara Rao, Trepanning of Al2O3 by electro-chemical discharge machining (ECDM)process using abrasive electrode with pulsed DC supply International Journal of Machine Tools & Manufacture,vol.47 (2007), pp V.K. Jain, S. Adhikary On the mechanism of material removal in electrochemical spark machining of quartz under different polarity conditions journal of materials processing technology vol.200 (2008), pp B.R.Sarkar, B. Doloi, B. Bhattacharyya, Parametric analysis on electrochemical discharge machining of silicon nitride ceramics International Journal of advanced manufacturing technology, vol.28 (2006), pp B. Doloi, B. Bhattacharyya and S. K. Sorkhel, Electrochemical Discharge Machining of Non-Conducting Ceramics. Defense Science Journal, vol. 49 (August 1999), pp M.L.Harugade, M.V.Kavade, N.V.Hargude, Effect of electrolyte solution on material removal rate in electrochemical discharge machining International conference of advanced manufacturing technology vol.1 (March2013), pp Manufacturing process for engineering materials, fifth edition, by Serope Kalpakjian, steven are schmid, by Pearson publication. 14. Production technology, HMT Bangalore Tata McGraw-Hill, Education 28 th reprint2008, ISBN -13: Chemistry part-i, Maharashtra state board of secondary and higher secondary education, Pune Shruthi. M, Lokesh K. S and Krishna B. M, Electrochemical Treatment Technology in Biodigester Effluent Treatment (BDE) International Journal of Civil Engineering & Technology (IJCIET), Volume 5, Issue 9, 2014, pp , ISSN Print: , ISSN Online: Piyush Chandra Verma & Ajay Gupta, Study of Electrochemical Oxidation Behaviour of High Build Epoxy, Cold Applied Poly Defined Tape and Polyurethane Coating System In Saline Environment International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp , ISSN Print: , ISSN Online:

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