ScienceDirect

Available online at www.sciencedirect.com

ProcediaScienceDirect
Manufacturing 00 (2018) 000–000
Available
Availableonline
onlineatatwww.sciencedirect.com
www.sciencedirect.com www.elsevier.com/locate/procedia
Procedia Manufacturing 00 (2018) 000–000
www.elsevier.com/locate/procedia
ScienceDirect
ScienceDirect 
Procedia Manufacturing 26 (2018) 469–473
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
Taguchi’s Methodology Based Electrochemical Discharge
Taguchi’s Methodology
Machining Based Matrix
of Polymer Electrochemical
Composites Discharge
Machining
Manufacturing Engineering of International
Society Polymer Matrix Composites
Conference
2017, Vigo (Pontevedra), Spain
2017, MESIC 2017, 28-30 June
Parvesh Antil, Sarbjit Singh, Perminder Jit Singh*
*
Costing modelsParvesh
for capacity
Antil, Sarbjitoptimization
Singh, Perminder in Industry
Jit Singh 4.0: Trade-off
between used capacity and operational efficiency
Punjab Engineering College (Deemed University), Sector 12, Chandigarh 160012, India

* Corresponding author. Tel.:Punjab Engineering College (Deemed University), Sector 12, Chandigarh 160012, India
+91-9988688691.
A. Santana , P. Afonso , A. Zanin , R. Wernke
E-mail address: perjay2000@yahoo.com
* Corresponding author. Tel.: +91-9988688691.
a a,* b b

E-mail address: perjay2000@yahoo.com a University of Minho, 4800-058 Guimarães, Portugal

Abstract b
Unochapecó, 89809-000 Chapecó, SC, Brazil

Abstract
The polymer composites has gained its reputation among advance materials in recent years due to their prominent mechanical
properties. Still, the machining of these materials induces lots of problem because of their fibrous nature. In this paper, an attempt
The polymer
Abstract
has been made composites
to machine has micro
gained hole
its reputation
in polymeramong advance
matrix materials
composites in recent
(PMCs) years
using due to their prominent
electrochemical discharge mechanical
machining
properties. Still, theThe
(ECDM) process. machining of these materials
experimentation was basedinduces lots of problem
on Taguchi’s because
methodology andofresults
their fibrous nature. Inqualitatively
were analyzed this paper, an
as attempt
well as
has
Under beenthemade
quantitatively. to machine
Voltage,
concept microconcentration
ofelectrolyte
"Industry hole
4.0",in production
polymer matrix composites
and inter-electrode
processes gap (PMCs)
willwere
be used using
as
pushed toelectrochemical
input process discharge
parameters
be increasingly whereasmachining
material
interconnected,
(ECDM)
removal rate
information process.
basedThe
(MRR) experimentation
was
on a observed
real timeasbasiswasand,
output based oncharacteristic.
quality Taguchi’s
necessarily, methodology
much The ofand
the results
stateefficient.
more machinedwerehole
In this analyzed qualitatively
was analyzed
context, capacity theasscanning
well as
byoptimization
quantitatively.
electron microscopeVoltage, electrolyte
(SEM). concentration
Analysis of varianceand inter-electrode
(ANOVA) gap were
was used used
to find outasmost
inputinfluential
process parameters whereas material
process parameters during
goes beyond
removal the traditional aim of capacity maximization, contributing also for organization’s profitability and value.
ECDM ofrate
PMCs(MRR) was observed
for each response. as output quality characteristic. The state of the machined hole was analyzed by the scanning
Indeed, lean management
electron microscope and continuous
(SEM). Analysis of varianceimprovement
(ANOVA) wasapproaches
used to find suggest
out most capacity
influentialoptimization instead
process parameters of
during
maximization.
ECDM of PMCsThe study
for each of capacity optimization and costing models is an important research topic that deserves
response.
contributions
© 2018 The Authors.from both the practical
Published andB.V.
by Elsevier theoretical perspectives. This paper presents and discusses a mathematical
© 2018 The Authors. Published by Elsevier B.V.
model for
Peer-review capacity
under management
responsibility of based
the on different
scientific committee
Peer-review under responsibility of the scientific committee
costing
ofthe
of
models (ABC and TDABC). A generic model has been
NAMRI/SME.
4th International Conference on System-Integrated Intelligence.
© 2018 Theand
developed Authors.
it wasPublished by Elsevier
used to analyze idleB.V.
capacity and to design strategies towards the maximization of organization’s
Peer-review
value.
Keywords: under responsibility
TheElectrochemical
trade-off Dischargeof
capacity the scientific
maximization
Machining; committee
vs Removal
Material ofRate;
NAMRI/SME.
operational efficiency is highlighted
Polymer Matrix and it is
Composites; Taguchi’s shown that capacity
Methodology
optimization might hide operational inefficiency.
Keywords: Electrochemical Discharge Machining; Material Removal Rate; Polymer Matrix Composites; Taguchi’s Methodology
© 2017 The Authors. Published by Elsevier B.V.
1. Introduction
Peer-review admirably Engineering
under responsibility of the scientific committee of the Manufacturing used in aerospace, marine and
Society International in other
Conference
2017. industrial applications [1]. But composites which are
1.
TheIntroduction
adaptable nature of polymer matrix composites admirably
made of glass used fibers
in aerospace, marine precise
requires highly and in micro
other
has increased
Keywords: Cost Models;their utilization
ABC; TDABC; CapacityinManagement;
industrial industrial
Idle Capacity;drilling
applications
operations
Operational
[1]. But composites which
Efficiency for assembly in the field of
are
The adaptable nature of polymer matrix
applications in last one and half decade. The broad composites made of glass fibers requires highly
automobile and aerospace [2]. The composite precise micro
has
use ofincreased their motivated
these materials utilizationthe in industrial
researchers to drilling
reinforcedoperations
with abrasivefor particles
assemblylikeinalumina,
the field of
boron
applications
1. in
Introduction last one and half
develop new improved composites which can be decade. The broad automobile and aerospace [2]. The
carbide, and silicon carbide causes complications composite
use of these materials motivated the researchers to reinforced with abrasive particles like alumina, boron
develop
The new
cost of improved
idle capacity composites
is a fundamentalwhich
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
can be
information for carbide, and
companies andtheir
silicon carbide ofcauses
management complications
extreme importance
in modern production
Peer-review systems.
under responsibility of theInscientific
general, it is defined
committee as unused capacity or production potential and can be measured
of NAMRI/SME.
in several©ways:
2351-9789 2018 Thetons of production,
Authors. available
Published by Elsevier B.V.hours of manufacturing, etc. The management of the idle capacity
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
NAMRI/SME.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 4th International Conference on System-Integrated Intelligence.
10.1016/j.promfg.2018.07.055
470
2 Parvesh
Parvesh Antil etAntil et al. / Procedia
al./ Procedia
Manufacturing
because presence of abrasive particles in the matrix
affects the drilling behavior of composites by high
tool wear and higher surface roughness of the drilled
hole [3]. The unconventional machining methods like
electrochemical discharge machining can be useful
method to remove these obstacles. This process was
first familiarized by Kurafuji in late sixth decade of
20th century [4]. Electrochemical discharge
machining is an unconventional machining process
which can be used to machine nonconductive brittle
materials [5] within low cost and efficacious time
limits with enriched surface quality [6].
The ECDM process starts when supplied voltage
passes critical and discharge initiates between
electrode and adjacent electrolyte. In general, ECDM
process (as shown in Figure 1) is a pool effect of two
processes namely electro-chemical machining (ECM)
in which metal is removed
by electrochemical process used for machining of
extremely hard electrically nonconductive materials
and electrical discharge machining (EDM) in which
metal is removed by quick current discharges
between two electrodes which are separated by a
dielectric liquid and subject to an electric
voltage. During experimentation, the material
which is to be machined is placed normally below the
tool electrode and immersed in an electrolyte. The
tool electrode is immersed up to few mm in the
electrolyte while the auxiliary electrode is placed a
few cm away from cathode electrode. A DC power
supply source is used for initiation of the electrolysis
process. When applied voltage is lowered than
critical voltage i.e. puncture strength of the gas film,
the electrolysis process starts and hydrogen bubbles
generate on cathode tip. With the increase in current
density at cathode electrode, the size of hydrogen
bubbles increases and coalescence to form a gas film.
This gas film act as an insulating layer between tool
electrode and electrolyte. As the applied voltage is
higher than puncture strength of the gas film, the
spark is initiated. The spark produced in the close
vicinity of tool electrode results in melting,
vaporizing and thermally eroding of the workpiece
due to discharge energy [7].
In recent times, the research fraternity has increased
their efforts in exploring the output quality
characteristics of ECDM process. Bhondwe et al. [8]
explored that electrolyte concentration, higher duty
factor, and energy partition are directly proportional
Manufacturing
26 000–000
00 (2018) (2018) 469–473
to material removal rate during ECDM of soda lime
glass. Kirchner [9] during his research revealed the
possibility of creation of microstructures on hard
metals without tool wear with electrochemical
machining using extreme tiny pulses. Rajurkar et al.
[10] and Kim et al. [11] claimed that brilliant surface
can also be attained without surface treatments. Gosh
et al. [12] recommended the use of electrochemical
discharge phenomenon in achieving micro-welding
of the workpieces. Apart of these potentials,
performance of machining process depends on
optimal combination of process parameters. The
optimal setting for drilling process parameters to
optimize output response can be effectively obtained
by Taguchi’s methodology [13]. The multi-response
optimization of ECDM process can be effectively
done with the help of Grey Relational Analysis
(GRA) [14].
Fig. 1 Schematic Representation of ECDM Process
2. Experimental Planning and Set up
The microhole of the glass fiber reinforced polymer
matrix composite was performed on the
electrochemical discharge machining setup as shown
in Figure 2. The workpiece material is composed of
two types of glass fibers in the form of E glass
chopped strand mat and S glass woven fabric along
with Araldite epoxy and hardener as matrix. The
cross-sectional view of fabricated composite is
shown in Figure 3. The bonding between glass fibers
and epoxy is clearly visible in SEM of fabricated
composite. Three process parameters named as
electrolyte concentration, voltage, and inter-electrode
gap were used as input parameters while material
removal rate was observed as output quality
characteristics. All input parameters have three levels
each. The various process parameters used during
machining are shown in Table 1 along with their
 Parvesh Antil et al. / Procedia Manufacturing 26 (2018) 469–473 471
Parvesh Antil et al./ Procedia Manufacturing 00 (2018) 000–000 3

levels. The experimentation was planned through 3. Results and Discussion

Taguchi’s experimental design employing L9
orthogonal array. The design layout of the
experiments is shown in Table 2.
Fig. 2 Experimental Setup for ECDM
Based on the experimental design L9 as shown in
Table 2, the experiments were conducted and for
each experiment, two repetitions were performed.
Generally, three replicates are performed for
experimental analysis where the gap in results is
higher than expected. In that case, the mean of the
observed results is used as final result. But in present
work, the variation in first experiment and second
repetition was very less. The workpiece material was
weighted before and after machining by electronic
weighing machine Denver SI 234 having least count
of 0.001 gram. The weight loss per unit time during
machining was termed as material removal rate and
calculated as milligram per minute. The obtained
results for MRR is shown in Table 3. The individual
response optimization is performed using Taguchi’s
methodology in which the initial task is to convert the
obtained response characteristics into signal to noise
(S/N) ratio which will be used as assessment index
for responses. Depending upon the required response
characteristics, generally, two types of S/N ratio
criteria are followed by the researchers which are
higher the better and lower the better [15]. For lower
the better, the S/N ratio can be calculated as follows:

1
n 

 ij  10 log  yij2  (1)
 n i 1 
 

1
n
1  
ij  10 log 
 n  2
yij 
(2)
 i 1 

Fig. 3 Cross-Sectional SEM of Fabricated PMC Here 𝑦𝑦𝑖𝑖𝑖𝑖 is the ith experiment at jth test and n is the
total number of tests. In the present research work,
Table 1 Process Parameters and their Levels higher the better S/N ratio criterion has been
Symbol Process Parameters Level 1 Level 2 Level 3 followed for MRR.
E Electrolyte Conc. (g/l) 90 100 110
V Voltage (Volts) 50 60 70
I Inter Electrode Gap (mm) 100 120 140
Table 3 Obtained Results
Exp. No. MRR1 MRR2 Mean S/N Ratio
1 1.110 1.114 1.112 0.92210
Table 2 L9 Orthogonal Array 2 1.182 1.184 1.183 1.45969
Exp. No. Electrolyte Conc. Voltage Inter Electrode Gap 3 1.191 1.193 1.192 1.52553
1 1 1 1 4 1.169 1.165 1.167 1.34142
5 1.179 1.185 1.182 1.45235
2 1 2 2 6 1.275 1.277 1.276 2.11701
3 1 3 3 7 1.151 1.157 1.154 1.24412
4 2 1 2 8 1.280 1.286 1.283 2.16453
5 2 2 3 9 1.288 1.290 1.289 2.20506
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2
472 Parvesh Antil et al. / Procedia Manufacturing 26 (2018) 469–473
4 Parvesh Antil et al./ Procedia Manufacturing 00 (2018) 000–000

Table 4 Analysis of Variance for MRR then up to level E3. The main reason for this trend
Source Symbol DF SS MS p-Value % Cont. with higher concentration is the incremental degree
E E 2 0.0095 0.0047 0.05 29.93 of dissolution efficiency at high concentration is
V V 2 0.0181 0.0090 0.03 56.53
I I 2 0.0037 0.0018 0.13 11.71
lesser as compared to low concentration [16]. The
Error 2 0.0005 0.0002 1.8 observed trends for applied voltage shows that with
Total 8 0.0320 increase in level of voltage, the MRR keeps
DF- Degree of Freedom, SS - Sum of Squares, MS - Sum of Mean increasing. Because increase in voltage increases the
Squares
rate of spark generation in spark zone [17]. The
increase in inter-electrode gap decreases the MRR as
the spark assisted zone decreases with increased
space between electrodes which further increases
interelectrode gap resistance [18]. From the observed
results, the optimal process parameters for the highest
MRR are found to be E3 V3 I1. For numeric and
category terms, the optimal values are Electrolyte
concentration at 110 g/l, Voltage at 70 V and Inter
electrode gap of 100 mm.
The SEM image of the through micro hole machined
by the ECDM process at 100x magnified view is
shown in Figure 6. The image shows clear cutting
and removal of fibers from surface of the composite
Fig. 4 Contribution of Various Process Parameters material. The effective removal of fiber residual
during initial stage of machining helps in suitable
movement of electrolyte. This uniform action of
electrolyte flushes out the residual material and
generates uniform spark during further machining
process. Slightly nonuniformity of diameter is present
at outer face of hole which is due to nonconductive
nature of polymer matrix composites. These
composites are difficult to machine with the help of
conventional drilling machines because these
materials are reinforced with glass fiber and silicon
carbide particles which causes high tool wear and
delamination during machining.

Fig. 5 S/N Ratio and Raw Data for MRR

The primary aim of the research investigation was to

obtain optimal parametric combination which can
provide best possible material removal rate during
machining. To obtain best possible parametric
combination, results were optimized individually for
each response characteristics. The ANOVA shown in
Table 4 depicts that voltage and electrolytic
concentration are most influencing parameters during
electrochemical discharge machining of glass fiber
reinforced polymer matrix composites. The observed
percentage contribution of each parameters is plotted
Fig. 6 SEM Image of Machined Hole
in graph as shown in Figure 4. The S/N ratio and raw
data graph for material removal rate during ECDM is
4. Conclusions
shown in Figure 5. The graph depicts that MRR
increases at steady rate from level E1 to level E2 and
From the experimental investigation using L9
 Parvesh Antil et al. / Procedia Manufacturing 26 (2018) 469–473
Parvesh Antil et al./ Procedia Manufacturing 00 (2018) 000–000
orthogonal array generated by Taguchi design of
experiments, following conclusions were drawn from
the study:
 The developed electrochemical discharge
machining setup can be effectively used for
the machining of fibrous composites.
 Using Taguchi’s methodology, the optimal
parametric combination for MRR are found
to be E3 V3 I1. i.e. Electrolyte concentration
at 110 g/l, Voltage at 70 V and Inter
electrode gap of 100 mm.
 The observed trends for each process
parameters shows that MRR during ECDM
of PMCs is directly proportional the voltage
and electrolyte concentration whereas
inversely proportional to the inter-electrode
gap.
 The absence of broken fibers and residuals
inside boundary wall confirms the through
drilling of hole. Also, the SEM at 100x
magnification shows that even fibrous
material can produce nearly uniform hole
during ECDM.
References
[1] P. Antil, S. Singh and A. Manna, Glass fibers/SiCp
reinforced epoxy composites: Effect
environmental conditions. Journal of Composite
Materials, (2017) DOI: 10.1177/0021998317723448
[2] M.S. Rahamathullah and Shunmugam, Mechanistic
approach for prediction of forces in micro-drilling of
plain and glass-reinforced epoxy sheets. Int J Adv
Manuf Technol, 75 (2014) 1177-1187.
[3] S. Singh, Study of drilling behavior of aluminium
6061 metal matrix composites using Taguchi's
methodology. International Journal of machining and
machinability of materials, 18 (2016) 327-340.
[4] H. Kurafuji, Electrical discharge drilling of glass. I.
Annals of CIRP, 16 (1968) 415-419.
[5] M. Cotea, H.P. Schulze, L. Slatineanu, Drilling of
difficult-to-cut steel by electrochemical discharge
machining. Materials and Manufacturing Processes,
26 (2011), 1466-1472.
[6] R. Wuthrich, V. Fascio, Machining of non-
conducting materials using electrochemical
discharge phenomenon - an overview. International
Journal of Machine Tools and Manufacture, 45
(2005) 1095-1108.
[7] P. Antil, S. Singh and A. Manna, A study on input
parameters affecting material removal rate and
surface roughness in electrochemical discharge
473
5
machining process, International Journal of Advance
Research in Science and Technology, 3(2014) 400-
405.
[8] K.L Bhondwe, V. Yadava and G. Katherisan, Finite
element prediction of material removal rate due to
electrochemical spark machining. International
Journal of Machine Tools & Manufacture, 46 (2006)
1699-1706.
[9] V. Kirchner, Electrochemical micro structuring with
ultrashort voltage pulses”, Ph.D. thesis, (2001) Free
University of Berlin.
[10] K.P. Rajurkar, D. Zhu, J. McGeough, J. Kozak, A.
De Silva, New developments in electro- chemical
machining. Annals of the CIRP, 48 (1999) 567-579.
[11] B.H. Kim,S.H Ryu, D.K. Choi,C.N. Chu, Micro
electrochemical milling. J. Micromech. Microeng.
15 (2005)124-129.
[12] A. Ghosh, M.K. Muju,S. Parija and Allesu, Micro
welding using electrochemical discharge, Int. J.
Mech. Tools Manuf. 37 (1997) 1303-1311.
[13] S. Singh, A. Singh, I. Singh and A. Dvivedi,
Optimization of the Process Parameters for Drilling
of Metal Matrix Composites (MMC) Using Taguchi
Analysis. Advanced Materials Research, 410 (2012)
249-252.
[14] P. Antil, S. Singh and A. Manna, Electrochemical
of discharge drilling of SiC reinforced polymer matrix
composite using taguchi's grey relational analysis.
Arabian Journal for Science and Engineering, (2017)
DOI: 10.1007/s13369-017-2822-6.
[15] S. Singh, Effect of modified drill point geometry on
drilling quality characteristics of metal matrix
composite (MMCs). Journal of Mechanical Science
and Technology, 30 (2016) 2691-2698.
[16] B. Bhattacharyya, B.N. Doloi and S.K. Sorkhel,
Experimental investigations into electrochemical
discharge machining (ECDM) of non-conductive
ceramic materials”, Journal of Materials Processing
Technology, 95 (1999) 145-154.
[17] A. Manna and A. Kundal, Micromachining of
electrically non-conductive Al2O3 ceramic on
developed TW-ECSM Setup International Journal of
Manufacturing, Materials and Mechanical
Engineering, 1 (2011) 46-55.
[18] I. Basak and A. Ghosh, Mechanism of spark
generation during electrochemical discharge
machining: a theoretical model and experimental
verification. Journal of Materials Processing
Technology, 62 (1996) 46-53.