Effects of Sodium Chloride and Sodium Sulphate Solutions on the Output of the Electrochemical Machining
Electrochemical Machining is a term given to one of nontraditional machining that uses a chemical reaction associated with electric current to remove the material. The process is depending on the principle of anodic dissolution theory for evaluating material removal during electrochemical process. In this study, the electrochemical machining was used to remove 1 mm from the length of the a workpiece (stainless steel 316 H) by immersing it in to electrolyte (10, 20 and 30 g) of NaCl and Na2SO4 to every (1 litter of filtered water). The tool used was made from copper. Gap size between the workpiece and electrode is (0.5) mm. This study focuses on the effect of the changing the type and concentration of electrolyte solution, the effect of the value of current (2, 5 and 10) A and the effect of the value of the voltage (6, 12 and 20)V on the Surface Roughness (Ra) and Material Removal Rate (MRR) of the workpiece. The results of comparison of experimental showed that (Na2SO4) solution give surface roughness less than (NaCl) solution in all levels, maximum (Ra) is (0.658) and minimum (0.420), while (NaCl) solution give maximum (Ra) is (2.913) and minimum is (0.508), also give (MRR) higher from (NaCl) solution in level (30 g/l ) at (5 A) , (10 and 20 g/l) at (10 A) ,and (30)g/l at (6 &12 V). This study aims to compare the effect of using different electrolyte solution including sodium chloride (NaCl) and sodium sulphate (Na2SO4) on the surface roughness (Ra) and material removal rate (MRR).
Generally increasing in machining parameter (concentration of solution, current and voltage) lead to increase in (MRR) and (Ra).
U. Mallick, "Estimation of MRR by using U-shape Electrode in Electrochemical Machining", M.Sc thesis, National Institute Technology, India, 2009.
C. Hee Jo, B. Hyun Kim, H. Shik Shin, D. Kwan Chung, M. Ho Kwon,C. Nam Chu" Micro Electrochemical Machining for Complex Internal Micro Features" International Conference on Smart Manufacturing Application, vol.143 pp. 247–250,2008.
K. P. Maity and N. K. Verma, "Multi-Response Analysis of Electrochemical Machining Process Using Principal Component Analysis ", Department of Mechanical Engineering National Institute of Technology, Rourkela, PP.153-160, 2010.
D. Chakradhan and A. Venu Gopal, "Multi-Objective Optimization of Electrochemical Machining of EN31 Steel By Grey Relational Analysis ", International Journal of Modeling and Optimization, Vol.1, No.2, PP.113-117, India, 2011.
B. R. Acharya, C. P. Mohanty and S. S. Mahapatra, "MultiObjective Optimization of Electrochemical Machining of Hardened Steel Using NSGA.II", Procardia Engineering, Vol.51, PP.554-560, 2012.
S.S. Uttarwar and Dr. I. K. Chpde, " A study of Influence of Electrochemical Process Parameters on The Material Removal Rate and Surface Roughness of SS AISI 304", International Journal of Computational Engineering Research, Vol.33, No.3, PP.189-196, India, 2013.
S.S. Uttarwar and I. K. Chpde, "Experimental Study of Effect of Parameter Variation on Output Parameters for Electrochemical Machining of SS AISI 202", IOSR Journal of Mechanical and Civil Engineering, Vol.5, No.5, PP.65-71, India, 2013.
J. Cirilo da Silva Neto , E. Malaquias da Silva , M. Bacci da Silva,"Intervening variables in electrochemical machining", Journal of material processing technology, vol.179, pp.92 – 96, Brazil, 2006.
A. Kumar Meher, "ECM Process Characteristics", B.Scs. Project, National Institute of Technology, Rourkela, 2009.
A. Sudiarso, A. A. Aladiat, and M. Mahardika, “Study on characteristics of electrochemical machining in producing multilayered microfilters,” AIP Conf. Proc., vol. 1755, no. 2016.
H. Hocheng, Y.H. Sun, S.C. Lin and P.S. Ka0, "A Material Removal Rate Analysis of Electrochemical Machining Using FlatEnd Cathode", Journal of Material Processing Technology, vol.140, pp.264-268, 2003.
B. Bhattacharyy, M. Malapati, J. Munda, A. Sarkar, " Influence of tool vibration on machining performance in electrochemical micro-machining of copper", Journal of material processing technology, vol.47, pp.335 – 342, India, 2007.
V. Sathiymoorthy, T. Sekar, P. Suresh, R. Vilayan and N. Elango, "Optimization of Processing Parameters in Electrochemical Machining of AlSl 202 Using Response Surface Methodology", Journal of Engineering Science and Technology, Vol.10, No.6, PP.780789, India, 2015.
L. Wang and J. N. Gai, “Study on Optimization of Machining Parameters in Electrochemical Machining,” Adv. Mater. Res. journal, vol. 476–478, no. 6, pp. 375–378, 2017.
(Received 29 May 2019; accepted 28 October 2019)
Copyright: Open Access authors retain the copyrights of their papers, and all open access articles are distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution and reproduction in any medium, provided that the original work is properly cited. The use of general descriptive names, trade names, trademarks, and so forth in this publication, even if not specifically identified, does not imply that these names are not protected by the relevant laws and regulations. While the advice and information in this journal are believed to be true and accurate on the date of its going to press, neither the authors, the editors, nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied, with respect to the material contained herein.