Experimental study of Milling-Electro-Chemical Spark Machining

(M-ECSM) process on Borosilicate Glass

Vevek Kumar1, Vinod Yadava2
Motilal Nehru National Institute of Technology, Allahabad, Department of Mechanical Engineering,
Allahabad, Uttar Pradesh-211004, India
1 2
Emails: rme1310@mnnit.ac.in, vinody@ mnnit.ac.in

Abstract: Electrochemical spark machining (ECSM) which integrates electro-chemical machining (ECM) and
electro-discharge machining (EDM), is a new hybrid machining process for shaping electrically non
conductive materials. The process employs synergetic interactive effect of electrochemical action and
electro-discharge action to increase machining performance. This paper presents an investigation on the
experimental study and machining parameter design of Milling-Electrochemical Spark Machining (M-ECSM).
The M-ECSM setup has been developed and experiments were conducted on Borosilicate glass workpiece
under varying voltage, Electrolyte concentration, pulse-on time, and pulse-off time which effect on Material
removal rate (MRR). The optimum machining parameters and settings of machining parameters were
determined by using One-Parameter- at-time (OPAT) approach.
.

Keywords: Milling-Electrochemical Spark Machining (M-ECSM), Material removal rate

(MRR), Borosilicate glass, One-Parameter- at-time (OPAT)

1. INTRODUCTION: similar to arc discharge in gases. They proposed

Modern high technology industries are facing
challenges from machining of non- conducting
materials (Glass, Quartz, Ceramics, and
Composites), stringent design requirements (High
precision, Complex Shape, and High Surface
Quality), and machining cost. It is not possible to
machine complex shape with close tolerance and
fine surface quality by the traditional machining
process. To meet these challenges various non-
traditional machining processes are developed.
However each of them has their own advantage
and limitations. The technological improvement of
non-traditional machining process can be achieved
by combining two or more then two machining
process, which is termed as hybrid machining
process (HMPs). In HMPs are developed to exploit
the potential advantage of constituent process and
diminish their disadvantage. Electro-Chemical
Spark Machining (ECSM) is a hybrid machining
process, which combines the features of Electro-
Chemical Machining (ECM) and Electro-
Discharge Machining (EDM). ECSM was
presented for the first time in 1968 by Kurafuji and
Suda [1] as “Electrochemical Discharge Drilling”
for micro-holes in glass. Crichton and McGough
[2] proposed that electrical discharge between tool
electrode and electrolyte interface occurs due to
generation of electrolytic flow pattern caused by
flow stagnation and eddy. Bask and Ghosh [3]
proposed the discharge phenomenon as switching
off phenomenon in electrical circuits. Jain et al. [4]
have considered each gas bubble as a valve, which
after its break down due to high electrical field
produces discharge in the form of spark. Kulkarni
et.al [5] proposed the discharge phenomenon
that hydrogen gas bubbles get accumulated at the
tool-electrode tip leading to combining of bubbles
into a single large bubble which isolates the tip
completely from the electrolyte. Wuthrich [6]
explained the bubble coalescence based on
percolation theory. Cao et al. [7] investigated the
machining of 3-D micro-structures of glass
workpiece using micro electrochemical discharge
machining and obtained good surface
microstructures. Cheng et al. [8] stated that
Electrochemical Discharge Machining (ECDM)
was an alternative spark-based micro-machining
method for producing micro-holes and
microchannels in non-conductive hard and brittle
materials. Adhikary et al [9] investigated that
Electrochemical spark machining (ECSM) process
has been successfully applied for cutting of quartz
using a controlled feed and awedge edged tool.
Contrary to the common belief that only cathode
works as a tool, both cathode and anode have been
used as a tool, i.e. ECSM with reverse polarity
(ECSMWRP) as well as ECSM with direct polarity
(ECSWDP) have been used to machine quartz
plates. In ECSMWRP, deep crater on the anode (as
a tool) and work piece interface is formed because
of chemical reaction. Chemical analysis of
electrolyte solution after the ECSM experiments,
also agrees with the feasibility of dissolution of
quartz into solution due to chemical reaction.
Reverse polarity cuts quartz plate at a faster rate as
compared to the direct polarity. But in reverse
polarity overcut, tool wear and surface roughness
are higher as compared to the direct polarity
machining. Magnified view of the machined
surface also shows a difference in the mode of
material removal in ECSMWDP and ECSMWRP.
The cutting is possible even if we make auxiliary
electrode of small size. In conclusion, experiments
have revealed that cutting can be performed
simultaneously at both the electrodes (anode and
cathode) during ECSM. Coteata et al.[10 ] have
produced a machined microgroove in a steel with a
cylindrical tool of 200 µm diameter. Using SEM
found out the surface structure of the machining
area of micro hole. Yang et al. [11] stated that
Electrochemical Discharge Machining (ECDM)
was an alternative spark-based micro-machining
method for producing micro-holes and
microchannels in non-conductive hard and brittle
materials. Ziki et al. [12] demonstrated that Spark
Assisted Chemical Engraving (SACE) could be
used as a tool to change the surface texture of glass
micro-channels. Han et al. [13] proposed a new
type of micro-ECDM cutting tool for Micro
electro-chemical discharge cutting of glass and a
cylindrical tool with micro-textures on the surface
was used as a cutting electrode.Therefore, this
paper includes the basic experimental results of
profile generation like micro-channel on glass.
This paper also deals with the effects of different
process parameters like applied voltage(V),
electrolyte concentrations(gm/l), pulse on-time and
pulse off-time on different machining performance
characteristic such as material removal rate (MRR)
during micro-channel cutting on borosilicate glass.
touching the non-conducting workpiece such as
borosilicate glass.The auxiliary electrode is
vertical aluminium rod.The electrolyte reservoir
is attached with the side wall of the machining
chamber in order to supply electrolyte.The
workpiece holder attached with vertically up and
down movement (Z axis) of linear actuator with
stepper motor. The step angle of stepper motor is
1.80 and the rpm of stepper motor can be varied
from with stepper drive .For efficient machining
a gap between tool and workpiece is essential so
that electrolyte is always present between the
bottom of tool and top surface of workpiece for
generating sparks.A stepper motor controlled by
using reisitance-capictance circuit has been
designed and fabricated to control the feed of
tool to maintain a certain minimum gap between
tool and workpiece. The line sketch of tabletop
Milling-ECSM setup is given in fig.2.1

2. Experimentation

2.1 Development of Experimental Setup:

The research done today mainly focused on
experimenting the machining of various
materials and investigating the effect of different
parameters on the material removal rate. It was
shown that a large class of materials (glass,
quartz, various ceramics and others) can be
machined. Not only simple structures as holes
but as well as very complex structures like slots,
channels etc. can be machined. Milling-ECSM
setup has been designed and fabricated keeping
in view the fundamental mechanism of the
process and basic functional requirements of Fig. 2.1 Line diagram of tabletop Milling-
different parts. The setup was performed after ECSM setup
assembling various indigenously developed basic
components such as different type of system: The power supply system used in Milling-
(i)Power Supply system ECSM is mostly DC pulse power supply voltage
(ii) Electrolyte Supply system able to maintain across the cathodic tool-
(iii)Tool feeding system electrode and anodic auxiliary electrode
(iv) Machining chamber .Pulsating current has three parameters such as
The machining chamber of size pulse on-time, pulse off-time and peak current
500mmx300mmx100mm is made of Plexiglass density. The main 230 volts, 3 phases, AC power
keep the electrolyte as some property such that supply are converted to low voltage DC power
an electrically insulating, transparent and supply by a step down transformer and silicon
corrosion resistant material. It is kept on the controlled rectifier unit. Here, the positive
lower plateform of wooden table .Within terminal of the power supply unit is connected
machining chamber the tool electrode is just with auxiliary electrode and one end of the coil
heating the electrolyte. The negative terminal of
the power supply unit is connected with tool and
another end of auxiliary electrode. Thus,
temperature of the electrolyte is controlled
electrically from 20oC to 60oC. Electrolyte
supply system consist of a pump anda flow
control valve.The electrolyte is supplied to the
cutting site on the work specimen can be
immersed thoughly in the electrolyte. An
electrolyte is fed with high velocity there will be
no formation of insulating layer or gas bubbles.
Hence for this thermal consideration the
electrolyte should be added drop by drop.
2.2 Experimental planning
Experiments of Milling-ECSM have been
carried out by varying machining parameters on
the machining characteristics and borosilicate glass
was used as a workpiece material. The ranges of
input parameters were decided for a quality cut on
the basis of machining capability, past experience,
literature review and exhaustive pilot experiments.
Performing an experiment more than once i.e.
replicating the experiment can often reduce the
effects of variability on experimental results.
Single set of experiment will not give any
indication of variability. Variability on
experimental results can be precisely captured by
increasing the number of repetitions of each set of
experiments though experimental cost will
increase. Minimum two repetitions are required to
avoid variability on experimental results. Three
repetitions are the appropriate from both point of
view i.e. capturing the variability and avoiding the
unnecessary increase in experimental cost. Hence,
it was decided to complete three repetitions in each
set of experiment. A aluminium rod of diameter 40
mm and length 150 mm was used as anode and
brass tool of diameter 10 mm was used as cathode
during experiments of Milling-ECSM process.
Here tool made of brass and their specification of
design in shown fig. 2.2.
20 mm
40 mm
5 mm
10 mm
Fig. 2.2 Schematic diagram of the Tool (Brass)
A rectangular borosilicate glass of size 50 mm×40
mm×8 mm was adopted as a workpiece because of
electrically non-conductive nature. borosilicate
glass has wide application in the field of defense
industries, aerospace industries, electronics
industries and nuclear industries etc.The material
properties and chemical composition of borosilicate
glass workpiece are tabulated in Table 2.1.
Table 2.1 Material properties of Borosilicate glass
Composition SiO2 B2O3 N2O Al2O3
Percentage 80.6% 13.0% 4.0% 2.3%
Property Quantity Unit
Specific Heat 750 Cp (J/Kg ºC)
Thermal Conductivity 1.14 k (W/m ºC)
Temperature 820 Tm (oC)
Specific density 2,230 ρ (kg/m3)
Workpiece specimen was held at constant
distance of about 45 mm from the anode. Cathode
(tool) was always kept in physical contact with
the workpiece which was mounted on the
supporting platform. It was observed that brass
tool starts to break if input voltage was above 85
V because of its low current carrying capacity. It
was also observed that there was no spark below
85 V. Hence, voltage was decided within the
range of 85 V to 95 V and current range of 0.5 A
to 10 A. Very low feed would lead to the situation
similar to the stationary tool resulting in no spark
because at point not a sufficient chemical reaction
take place. Hence, tool during arrangement was
made through the stepper motor within range of
1.0 m/min to 2.4 m/min with stepper drive 5 to
25000 revelution per min. NaOH was used as
electrolyte because it has high specific
conductance and high reaction rates and hence,
larger amount of gases were evolved which leads
to higher MRR. Thus, all the experiments
reported in this work were carried out using
NaOH solution as electrolyte. An aqueous
solution of NaOH with a range of 300 g/l to 400
g/l solution at 20ºC to 40ºC was used. Each
experiment was tested for about 10 min. each,
The range of feed rate used in the present work
was taken 0.008mm/s to 0.01mm/s. The feed rate
has been obtained by dividing the length of cut
with the time required for complete cutting of the
workpiece. Therefore, a reliable experimental data
has been used for the analysis of Milling-ECSM
process. The pulsating D.C. power supply has
been used during the experiments due to better
spark stability and more spark energy than
constant D.C. power. Hence, experiments carried
out using pulse on-time with the range of 500 µs
to 700 µs and pulse off-time with the range of 400
µs to 600 µs respectively with pulse D.C. source.
Linear actuator
with steeper motor
(Z axis)
Machining
chamber
Tool
fig. 2.3 Photographic view of working platform
In the present work one performance parameters
analyzed are MRR. For determination of MRR, the
loss in weight of the machined specimen was
measured on a weighing digital microbalance
(accuracy 10 µg, CAS India Private Limited). After
machining, the workpiece was washed, dried to
evaporate any water remaining on the surface and
reweighed using a weighing digital micro balance.
The difference between the initial weight and the
final weight represents the material removed during
machining.
The volume removed per unit time was used to
determine MRR using the formula given below:
Wb - Wa
MRR =
t×ρ
Where, Wb = Weight of workpiece before
machining in gram,
Wa = Weight of workpiece after
machining in gram,
t = Machining time in minute
ρ = Density of workpiece in g/mm3.
3. Results and Discussion
The experimentation was successfully
completed using Milling-ECSM set-up. The effect
of input parameters such as applied voltage,
electrolyte concentration, pulse on-time and pulse
off-time on outputs MRR (gm/min) during Milling-
ECSM were studied on a rectangular workpiece
boroslicate glass of 8mm thickness. OPAT
approach is extensively used to study the behavior
of Electro-Chemical Discharge phenomena during
drilling, milling and grinding processes. In this
technique only one parameter is varied at a time in
particular range while other parameters are kept
constant value to study the performance .
Channel
fig. 2.3 Photographic view of borosilicate glass
on made micro channel
In this way, the effect of each individual input
parameter out of all possible input on output
parameter is investigated one by one. This
approach is very useful for deep understanding of
process behavior. OPAT may be preferred when
an experimenter wishes to react more quickly to
data and can be safely used in those cases in which
factor effects are three or four times the standard
deviation due to pure experimental error. This
dynamic interplay between model and experiment
is often an important part of engineering design.
3.1 Effect of Applied voltage
The effect of applied voltage on MRR in Milling-
ECSM process for keeping other parameter
constant in shown in figure 3.1 at pulse on-time
500µs and pulse off-time 600 µs wire velocity.
Here it is observed that MRR increase with
increase in various supplied voltage such as 85V,
90V, 95V. There is no spark below 85V and
randomly short circuiting problem above 95V .An
increase in applied voltage implies higer discharge
energy per spark hence more heat generated
resulting in MRR increase. However with increase
in voltage the electrolysis process is accelerated
hence the rate of generation of hydrogen gas
bubbles is increased and resulting the rate of
generation of discharge energy increase. At high
machining voltage, micro-crack from on work
surface has been obtained.
 MRR VS Applied Voltage tool. This is due to fact that the specific
conductance of NaOH solution increase upto 40%
0.56 concentration beyond which its start decreasing.
0.54 MRR VS Electrolyte concentration
0.52
0.035
0.50
400 µs
M R R (gm /m in)

0.48 0.030
500 µs
0.46 600 µs
0.025
0.44

MRR (gm/m in)

0.42 0.020
0.40
300 (gm/l) 0.015
0.38
350 (gm/l)
0.36 400 (gm/l)
0.010
0.34
84 86 88 90 92 94 96 0.005
Applied Voltage (Volt)
fig 3.1 Effect of Applied voltage on MRR 0.000
280 300 320 340 360 380 400 420
(at pulse on-time 500µs and pulse off-time 600 µs)
Electrolyte concentration (gm/l)

3.2 Effect of Pulse on-time

fig 3.3 Effect of Electrolyte Concentration on MRR
(at applied voltage 95 volt ,pulse on-time 700 µs)
The effect of pulse off-time on MRR for
borosilicate glass is shown in fig 3.2 for different
3.4 Effect of Pulse off-time
voltage.MRR decrease with the increase pulse off-
MRR increase with increase in different pulse off-
time .During pulse off-time 400 µs, electrolyte
time for keeping other parameter constant as shown
concentration 400 (gm/l) increase in voltage
in fig 3.4 at electrolyte concentration 350 gm/l,
implies higher discharge energy per spark hence
applied voltage 85 volt .It is clear from graph that
more heat generated resulting in enhanced MRR.
duty factor affect the material removal rate, the
However, with the increase in voltage the
MRR increase steadily with the increase
electrolysis process is accelerated hence ,the rate of
generation of hydrogen gas bubbles is increased
MRR VS Pulse off-time
and consequently the rate of generation of
discharge energy increase.
0.46
MRR VS Pulse on-time
500 µs
0.44 600 µs
0.135 700 µs

0.42
0.130 85 Volt
M R R (g m /m in )

90 Volt
95 Volt 0.40
0.125
M R R (gm /m in)

0.38
0.120

0.115 0.36

0.110 0.34

0.105 0.32
350 400 450 500 550 600 650

0.100 Pulse off-time (µs)

450 500 550 600 650 700 750

Pulse on-time (µs)

fig 3.4 Effect of Pulse off-time on MRR
fig 3.2 Effect of pulse on-time on MRR (at electrolyte concentration 350 gm/l, applied
(at pulse off-time 400 µs, electrolyte voltage 85volt)
concentration 400 gm/l) in level of Pulse off-time. An increase in the
3.3 Effect of Electrolyte Concentration pulse duration implies that more time has been
MRR increases with an increase in electrolyte allowed to machine the workpiece for fixed
concentration up to 45% and then start decreasing. duration because only during pulse duration
shown in fig 3.3. at applied voltage 95 volt ,pulse material takes place.
on-time 700 µs because at high energy instated
which overlapping the bubble (H2) accumulated of
 3.5 CONCLUSIONS mechanism in electrochemical discharge
The following conclusions are drawn as machining”, International Journal of
listed below: An in house Milling-ECSM of Machine Tools and Manufacture, (2002),
experimentation conducting OPAT on 42, 1121-1127.
borosilicate glass of non conducting hard and [6] Wuthrich, R. and Fascio, V., “Machining
brittle materials. of non-conducting materials using
i. MRR have been found to increase with an electrochemical discharge phenomenon-an
increase in supply voltage. It has also been overview”, International Journal of
observed that an increase in MRR at higher Machine Tools and Manufacture, (2005),
voltage . 45, 1095-1108.
ii. With increase in Pulse on-time,there is an
[7] Cao, X. D., Kim, B.H. and Chua, C.N.,
increase in material removal rate.It has also
“Micro-structuring of glass with features
been observed that MRR is more at pulse off-
less than 100µm by electrochemical
time 400 µs.
discharge machining”, Precision
iii. MRR also increase with an increase in
Engineering, (2009), 33,459-465.
electrolyte concentration upto around 45 %.
[8] Cheng, C.P., Wu, K.L., Mai, C.C., Yang,
After this it start decreasing because of higher
C.K., Hsu, Y.S. and Yan, B.H., “Study of
concentration the specific conductivity of
gas film quality in electrochemical
NaOH.
discharge machining”, International
iv. MRR increase with the increase pulse off-time.
Journal of Machine Tools and
At higher values of electrolyte concentration
Manufacture, 50 (2010) 689-697.
which results heat energy penetrates into the
[9] Jain, V.K. and Adhikary, S., “On the
workpiece and conquentenly larger value of
mechanism of material removal in
depth of crater.
electrochemical spark machining of quartz
under different polarity conditions”,
ACKNOWLEDGEMENTS
Journal of Materials Processing
Authors would like to thanks TEQIP-II,
Technology, (2008), 200, 460-470.
Motilal Nehru National Institute of Technology,
[10] Coteata, M., Schulze, H.P. and Slatineanu,
Allahabad for financial support.
L., “Drilling of difficult-to-cut steel by
electrochemical discharge machining”,
Journal of Materials and Manufacturing
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