Sei sulla pagina 1di 9

R V COLLEGE OF ENGINEERING

Bengaluru - 560059
Autonomous Institution Affiliated to
Visvesvaraya Technological University, Belagavi

Synopsis
for Project

Investigations on the effect of titanium coated


tungsten carbide drill bit in electrochemical
discharge machining of glass
Submitted by

A SAI SRINIVAS 1RV17MPD09


Under the Guidance
of
Jinka Ranganayakulu
Assistant Professor
Department of Mechanical Engineering
R.V College of Engineering
Bengaluru 560059
In partial fulfilment for the award of degree of
Master of Technology
in
Product Design and Manufacturing
Mechanical Engineering
2018-19
Synopsis
Title of the Project
Investigations on the effect of titanium coated tungsten carbide drill bit in electrochemical
discharge machining of glass

Introduction
Hard brittle materials such as glasses, engineering ceramics, and single crystals have favorable
characteristics – wear resistance, chemical resistance, a high melting point, and high strength.
Such materials are used in many industrial applications. Nevertheless, these excellent materials
are generally expensive. Also, most non-conventional machining processes, such as
electrochemical machining (ECM), electro discharge machining (EDM), etc., cannot be
utilized for the machining of electrically non-conducting materials. Electrochemical discharge
machining (ECDM) is such a process, that can be employed to machine electrically non-
conducting materials using the electrochemical discharge phenomenon. When two electrodes
of very different sizes are separated by a few millimeters and dipped into an electrolyte
solution, beyond a certain value of applied voltage, electric sparks appear across the electrode–
electrolyte interface on the smaller electrode and the cell current drops. This is known as the
electrochemical discharge (ECD) phenomenon. If the machining utilizes the ECD
phenomenon, then it is called ECDM. It is a hybrid technique, the combination of ECM and
EDM processes

Preliminary Literature Review


Weidong Tang et al. [1] has found that the side-insulated tool electrode achieves a smaller hole
diameter and better surface integrity without an obvious heat affected zone at the hole entrance.
Also, side-insulated electrode has an advantage in enhancing shape accuracy by reducing the
taper angle of the micro hole. When the machining depth is 600 μm, the side-insulated electrode
achieves a much smaller hole taper angle (3.3°) than the traditional tool electrode does (6.4°).
Cheng-Kuang Yang et al. [2] studied the wettability and machining characteristics of different
tool electrode materials and their impact on gas film formation. Their machining performance
and extent of wear under gravity-feed micro-hole drilling are also examined. Tungsten carbide
showed the best machining stability and least tool wear followed by tungsten and stainless steel
and the break down voltage was found between 26-30V during ECDM process. Differences in
tool material also results in variations in machining speed. Significant tool wear is observed
after repeated gravity-feed machining of 50 micro-holes.
Lijo Paul and Donald Antony [3] has found that smaller diameter tools has shown higher MRR
with lower ROC.
S. Saranya et al. [4] have compared a spherical tool tip and cylindrical tool tip their
investigations show that a tool with a spherical tip provides a profile with a reduced entrance
diameter and the overcut can be considerably reduced by controlling the tool feed-rate.
Chak and Rao [5] have carried out experimental study with spring fed cylindrical tools under
gravity feed mechanism with mixed electrolyte. They have reported that abrasive rotary tool
increased the machinability and MRR due to abrasive particles present in machining.
Yang et al. [6] also studied the tool geometry effect with a spherical end tool electrode
(diameter 150 μm) and cylindrical tool electrode (diameter 100 μm). Experimental results
showed that the curve surface on the spherical tool electrode reduced the contact area between
the electrode and the workpiece, thus facilitating the flow of electrolyte to the electrode end.
This enabled rapid formation of gas film, resulting in efficient micro-hole drilling. Comparison
between machining depth of 500 μm achieved by conventional cylindrical tool and spherical
tool electrode are carried out. The results showed that machining time was reduced by 83%.
Xuan Doan Cao et al. [7] has shown that the grinding process under PCD tools reduces the
surface roughness of ECDM structures from a few tens of a μm to 0.05 μm Ra, and the total
machining time of the hybrid process is less than a third compared to that under a conventional
grinding process.
Chak and Rao [8] have also carried out ECDM machining with mixed electrolyte of NAOH
and KOH on aluminum oxide workpiece material. It was found that the conductivity of the
electrolyte was higher with mixed electrolyte. This provided higher heating in machining area.
But beyond the saturation limit conductivity was found to same with higher concentration. In
the present paper machining is carried out on silicon wafers with mixed electrolyte of NaOH
and KOH with varying electrolyte concentration from 5% to 15 % wt. fraction in order to
improve the material removal rate in the process.
Rajendra Kumar Arya et al. [9] has developed a fresh electrolyte injection method through a
tubular electrode with precisely controlled electrolyte flow rate (EFR) into the machining zone
during ECDM. His investigation reveals that the injected fresh electrolyte enhances the
machining performance over conventional ECDM process. Also, the EFR is found to be
dependent on provided thermal energy inside the machining zone.
Tarlochan Singh et al. [10] has developed an ECDM with the pressurized feeding system was
successfully used for the fabrication of micro-holes on borosilicate glass up to 1537 μm depth.
The developed pressurized feeding system presents 207.4% improvement in machining depth.
Ashwin Varghese, Lijo Paul [11] investigated on Polypropylene (PP) materials with graphite
particle powder mixed electrolyte in ECDM Process in order to improve the machining. It is
found that multiple discharging effects were created on the work piece surface due to
conducting graphite particles in electrolyte.
Yi Xu et al. [12] experiments demonstrated that Counter resistance method has better
repeatability over conventional gravity-feed method. He also found that proper control of
varied forces exerted on tool electrode can enhance the micromachining performance. He also
observed that accumulation of bubbles near the hole entrance slowed electrolyte replenishment,
which is the main reason accounting for the tool bending.
Wuthrich et al. [13] investigated on, various tool feeding mechanism, voltage, tool shape and
force affecting the machining process. They have conducted consecutive machining at constant
voltage and constant tool diameter. They found that the process becomes similar, approaching
a repeatable situation because of steady-state distribution of the local temperature.
M L Harugade et al. [14] has studied the effect of different electrolyte solutions like H2SO4,
KOH, NaCl, NaOH and found that the acidic electrolyte solution (H2SO4) shows intermittent
and disturbed spark which result in excessive erosion of electrode and damage to the work-
piece. The salty electrolyte solution (NaCl) shows remarkable wear of tool however no damage
to work-piece is recorded. The basic electrolyte solution (NaOH, KOH) shows negligible wear,
constant spark and better surface finish of work-piece.
Yang et al. [15] investigated the effect of various electrolytes on the time of micromachining
of borosilicate experimentally. Their results showed that machining time in Hydroxide salts
(NaOH and KOH) is less compared to Chloride salts (NaCl and KCl).
Baoyang Jiang et al. [16] A FEA model was deployed in ABAQUS to simulate material
removal process in ECDM. In which material removal is treated as a heat transfer problem with
assumptions (1) material is removed by thermal melting (2) sparks bring inlet heat to the
workpiece. Material is considered to be removed once temperature reaches the melting point
of glass.
Mudimallana Goud and Apurbba Kumar Sharma [17] has developed a 3D FEM simulation
model to study the variation of temperature distribution in the workpiece and the variation of
MRR with respect to change in the input parameters like applied voltage and electrolyte
concentration. The simulation was carried out for two different materials—soda lime glass and
alumina (Al2O3).
Jalali et al. [18] developed a thermal analytical model to better understand the material removal
mechanism in gravity feed micro-hole ECDM drilling. They considered a hybrid mechanism
combining local heating and chemical etching for ECDM machining and compared it with
experimental data. Their study was focused on the hydrodynamic regime of ECDM drilling.
The estimation of the machining temperature was around 600°C as a result of the comparison
between model and experiment.
Ranganayakulu et al. [19] experimental results show that the material removal mechanism in
ECDM is non-linear – the volume of material removed decreases with increasing machining
depth. A soft computing approach called adaptive neuro fuzzy inference system (ANFIS) is
adapted to model the non-linear material removal rate. He also found that voltage had
predominant effect on MRR than electrolyte concentration and tool feed rate.
Lijo and Somashekhar [20] had conducted Response Surface Modeling (RSM) of ECDM
process with pulsating DC to understand the effect of various process parameters on micro hole
and micro channel machining to study the output response Material Removal Rate (MRR),
Tool Wear Rate (TWR), Heat Affected Zone (HAZ) and Radius of Over Cut (ROC). They
found that that the temperature of the electrolyte affects the machining process. MRR decreases
at higher depth due to lower spark energy which was due to unavailability of electrolyte.
Lijo and Somashekhar [21] have also carried out multi objective optimization with grey
relational analysis. They have made micro channels with optimized values. Reported that heat
affected zone in micro channels can be reduced with low duty factor during machining process.
Lijo et al. [22] also reported that higher frequency at low duty factor will increase MRR with
reduction in HAZ. Duty factor is found to be a predominant factor affecting the machining
characteristics.
Jain et al. [23] predicted the material removal rate in the ECDM drilling by modelling the
problem as a 3D unsteady state heat conduction problem. They adopted the heat source of the
spark as a prismatic column with squared cross section. They solved the mentioned problem
with the finite element method to compute the temperature distribution and the material which
attains equal 3 to or above the melting/softening temperature of the soda lime glass workpiece
(Tm/s=850°C) that is assumed to be removed. In the best situation (machining voltage 65V), the
compatibility of the model with the experimental data was about 35%. The assumed shape for
the heat source could be one of the error sources of the model because this shape is far from a
real-life situation.
Phipon and Pradhan [24] used Genetic Algorithm (GA) using MATLAB software to optimize
process parameters to minimize ROC and HAZ on silicon nitride ceramics in ECDM process.
It was also observed from GA analysis that, higher voltage results in larger ROC and medium
electrolyte concentration provide a low ROC.
Hajian et al. [25] investigated the effect of the magnetic field on the surface quality and the
depth of microchannels produced by ECDM milling. According to their results, in lower
electrolyte concentration, the magnetic field increases the bubble motion and enhances the
conductivity of electrolyte.
Hajian et al. [26] has observed a decrease in the bending force by increasing the electrolyte
concentration and elevating the applied voltage. In addition, the significant effect of a magnetic
field on the reduction of bending force in the lower concentration of electrolyte (15 wt.%) was
observed.

Problem Statement
From the literature it was found that minimum amount of research was carried out with coated
twist drill tool bit. Hence present work is mainly focusing on, to investigate the influence of
titanium coated tungsten carbide twist drill bit on machining performance in terms of material
removal rate, tool wear rate, heat affected zone and over cut in machining of borosilicate glass.

Objective of the Project


 To investigate the influence of coated tools on machining performance and compare
with the non-coated tools.
 To optimize processes parameters like voltage, electrolyte concentration, duty factor
and tool rotation.
 To develop and simulate a model for tool wear rate.
Methodology

Literature Review

Choosing Parameters and their Levels

Experimental Layout

Performing Experiments

Analysis of Results

Tool Wear Simulation

Comparison of Results with Simulation

Conclusion

1. Choosing parameters from speed, feed, voltage, current, duty factor, tool diameter
(Since it is not easy to study many parameters at once few parameters will be chosen
for study rest of the parameters will remain constant for all experiments)
2. Finding out number of levels for each parameter
3. Using design of experiments to generate experimental layout
4. Performing the experiments
5. Measure the response parameters and compare effects with respect to coated and
uncoated tool (response parameters are radial overcut (ROC), material removal rate
(MRR), tool wear rate (TWR), HAZ thickness
6. Using Minitab to perform ANOVA to find significance of various parameters
7. Tool wear simulation and comparison with the experiments conducted
Materials, Tools & Equipment
1. ECDM machine
2. Tungsten carbide tool
3. Workpiece
Software Requirements
1. Minitab 17
2. MATLAB
3. Autodesk Inventor 2019
4. Autodesk NASTRAN In-CAD
Timeline
References
[1] Weidong Tang, Xiaoming Kang and Wansheng Zhao, Enhancement of electrochemical
discharge machining accuracy and surface integrity using side-insulated tool electrode with
diamond coating, IOP Publishing, J. Micromech. Microeng. 27 (2017) 065013 (11pp)
[2] Yang CK. (2010). Effect of surface roughness of tool electrode materials in ECDM
performance. International Journal of Machine Tools & Manufacture 50: pp. 1088–1096.
https://doi.org/10.1016/j.ijmachtools.2010.08.006
[3] Lijo Paul and Donald Antony, Effect of tool diameter in ECDM process with powder mixed
Electrolyte, IOP Conf. Series: Materials Science and Engineering 396 (2018) 012070
doi:10.1088/1757-899X/396/1/012070
[4] S. Saranya, A. Ravi Sankar, Effect of Tool Shape and Tool Feed Rate on the Machined
Profile of a Quartz Substrate Using an Electrochemical Discharge Machining Process,
Proceedings of the 2015 2nd International Symposium on Physics and Technology of Sensors,
8-10th March, 2015, Pune, India
[5] Chak S K, Rao P V. Trepanning of Al2O3 by electro-chemical discharge machining
(ECDM) process using abrasive electrode with pulsed DC supply. International Journal of
Machine Tools and Manufacturing 2007; pp. 2061-2070.
[6] Yang, C., Ho, S., Yan, B.H., 2001. Micro hole machining of borosilicate glass through
electrochemical discharge machining (ECDM), Key Engineering Materials. Trans Tech
Publications pp. 149-166.
[7] Xuan Doan CaoBo, Hyun KimBo Hyun Kim, Chong Nam Chu, Hybrid Micromachining
of Glass Using ECDM and Micro Grinding, January 2012, International Journal of Precision
Engineering and Manufacturing, DOI: 10.1007/s12541-013-0001-6
[8] Chak S K, Rao P V. The drilling of Al2O3 using a pulsed DC supply with a rotary abrasive
electrode by the electrochemical discharge process. International Journal of Advanced
Manufacturing Technology 2008; 39, pp. 633-641.
[9] Rajendra Kumar Arya, Akshay Dvivedi, Journal of Materials Processing Technology
https://doi.org/10.1016/j.jmatprotec.2018.10.035
[10] Tarlochan Singh & Akshay Dvivedi (2018) On pressurized feeding approach for effective
control on working gap in ECDM, Materials and Manufacturing Processes, 33:4, pp. 462-
473, DOI: 10.1080/10426914.2017.1339319
[11] Ashwin Varghese, Lijo Paul, Effect of Powder Mixed Electrolyte in ECDM Process,
Materials Today: Proceedings Volume 5, Issue 5, Part 2, 2018, Pages 11864-11869
[12] Yi Xu, Jihong Chen, Baoyang Jiang, Jun Ni, Journal of Materials Processing Technology
2018, https://doi.org/10.1016/j.jmatprotec.2018.02.023
[13] Wüthrich R, Spaelter U, Wu Y and Bleuler H. A Systematic Characterization Method for
Gravity Feed Micro Hole Drilling in Glass with Spark Assisted Chemical Engraving (SACE).
J of Micromechanics and Microengineering 2006; 16: pp. 1891-1896.
[14] M.L.Harugade, M.V.K., N.V.Harude, Effect of electrolyte solution on material removal
rate in Electro Chemical Discharge Machining. Journal of Mechanical and Civil Engineering:
pp. 1-8.
[15] Cheng C-P, K-L W, Mai C-C, Yang C-K, Hsu Y-S, Yan B-H (2010) Study of gas film
quality in electrochemical discharge machining. Int J Mach Tools Manuf 50(8): pp. 689–697
[16] Baoyang Jiang, Shuhuai Lan, and Jun Ni, Investigation of micro-drilling assisted
electrochemical discharge machining, IWMF2014, 9th International Workshop on Micro
factories October 5-8, 2014, Honolulu, U.S.A, pp. 1-8
[17] Mudimallana Goud and Apurbba Kumar Sharma, A three-dimensional finite element
simulation approach to analyse material removal in electrochemical discharge machining,
Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical
Engineering Science 1989-1996 (vols 203-210) March 2016
[18] Jalali M, Maillard P, Wüthrich R. Toward a better understanding of glass gravity-feed
micro-hole drilling with electrochemical discharges. Journal of Micromechanics and
Microengineering. 2009, pp. 19:045.
[20] Lijo P, Somashekhar S H. Response Surface Modelling of Micro Holes in Electrochemical
Discharge Machining Process, Procedia Engineering 2013; Vol. 64, p.1395 –1404.
[21] Lijo P, Somashekhar S H. Characterization of Micro Channels in Electrochemical
Discharge Machining Process, Applied Mechanics and Materials 2014, pp. 490-491.
[22] Lijo P, Somashekhar S H. Evaluation of Process Parameters of ECDM using Grey
Relational Analysis. Procedia Materials Science 2014, pp. 2273-2282.
[23] Jain V, Dixit P, Pandey P, On the analysis of the electrochemical spark machining process.
International Journal of Machine Tools and Manufacture. 1999, pp. 65-86.
[24] Ruben Phipon and Pradhan B B. Optimization of electro-chemical discharge machining
process using genetic algorithm. IOSR J of Engineering 2012, pp. 106-115.
[25] Hajian, M., Razfar, M.R., Movahed, S., 2016. An experimental study on the effect of
magnetic field orientations and electrolyte concentrations on ECDM milling performance of
glass. Precision Engineering 45, pp. 322-331
[26] Hajian, M., Razfar, M.R. & Etefagh, A.H. Experimental study of tool bending force and
feed rate in ECDM milling, The International Journal of Advanced Manufacturing Technology
(2017), 91, pp. 1671-1677. https://doi.org/10.1007/s00170-016-9860-1

Potrebbero piacerti anche