performance study of electrochemical machining on metal matrix composite

Dogo Rangsang Research Journal UGC Care Group I Journal
ISSN : 2347-7180 Vol-10 Issue-08 No. 15 August 2020
Page | 194 Copyright @ 2020 Authors
Performance Study of Electrochemical Machining on Metal Matrix Composite
Kayinat Nazir1
, Er. Neeraj Kumar2
1,PG SCHOLAR,DEPARTMENT OF MECHANICAL ENGINEERING, R N COLLEGE OF
ENGINEERING & TECHNOLOGY, MADLAUDA, PANIPAT
2,ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL ENGINEERING, R N COLLEGE OF
ENGINEERING & TECHNOLOGY, MADLAUDA, PANIPAT
Email id : kayinat.n.g@gmail.com
Abstract
This research work mainly focuses on the effect of the influencing process parameters of EMM like machining
voltage, electrolyte concentration, frequency on the over cut and material removal rate (MRR) of five different
AMCs through taguchi and grey-relational analysis has been investigated experimentally from the economical
point of view. Experiments were conducted to determine the dominant process parameters on machining rate
and overcut. Finally, the undefined items- voltage, electrolyte concentration and frequency- are the machining
parameters used for the experiments. Machining current of 0.6 A and work piece thickness of 0.5 mm are the
fixed parameters in the experiment. In order to have a complete study of EMM process, the range of parameters
selected, and an appropriate planning of experimentation are essential to reduce the cost and time consumption.
Three factors, each set at three levels were taken for this research work for each AMC. Voltage (4 V -10 V),
Electrolyte concentration (18 g/l - 40 g/l) and Frequency (25Hz - 60 Hz) were considered as parameters.
Overcut (μm) and material removal rate (mg/min) are the important machining characteristics in EMM
operation and hence minimizing overcut and maximizing the material removal rate were taken as objective of
this research work. MRR is calculated as the difference of the initial and final weights of the workpiece, per unit
machining time. Overcut (radial overcut) of the machined micro-hole has been considered as a machining
accuracy criterion. It is the difference between the radius of the machined hole and the radius of the tool
electrode. Micro-hole radius were measured with the help of an optical microscope. Machining time is noted for
each experiment. Based on the machining time and micro-hole diameter, the MRR and overcut were calculated.
Hence, an experimental plan based on Taguchi’s L27 orthogonal array has been selected and 27 trials were
carried out for all five AMCs with different combinations of parameters levels. Taguchi methodology and grey
relational analysis were used to find the optimum EMM process parameters and the same to validate through
the confirmation test.
Keywords :- EMM, MRR,AMCs, Taguchi, L27 Orthogonal.,
1. INTRODUCTION
ECM metal removal is obtained by anodic dissolution of the work piece. The shape of the anodic dissolution will
be that of the mirror-image of the shape on the cathodic tool. Hard-metals can be shaped electrolytic ally by
using ECM and the rate of machining does not depend on their hardness. The tool’s electrode used in the process
does not wear, and therefore soft-metals can be used as tools to form shapes on harder work-pieces, unlike
conventional machining methods. The tool is guided towards the work-piece to maintain a constant inter-
electrode gap between them. This causes short-circuit between the electrodes and hence premature termination
of machining. Under short-circuit conditions the gap width goes to zero. Hence, a constant interelectrode gap
should be maintained for the machining operation to be carried out on the given work-piece.
A. Need for Electrochemical Micro Machining
In recent years, devices are becoming smaller and their features are increasing at the same time. Micro-
machining technology plays an increasing key role in the miniaturization of components ranging from bio-
medical applications to chemical micro-rectors and sensors. Since miniaturization will continue as long as
people require effective space utilization with more efficient and better accuracy products, micro-machining

technology will be still more important in the future. Micro-machining refers to small amount of material
removal of dimensions that ranges from 1 to 999 µm. The fabrication of microstructures by ECM is known as
electrochemical micro-machining (EMM). The machining gap (distance between the tool and the work-piece) of
conventional ECM is as large as 0.1–0.7 mm. If it is possible to make the machining gap of ECM smaller, then
ECM can be applied for micromachining (Kurita et al., 2006). Attempts to be made to shorten the machining gap
are:
Using pulsed power supply;
An insulating a film coating on the side surface of an electrode to prevent the undesired removal of work
material;
Controlling the electrode position by contact detection to maintain the micromachining gap;
Using an electrolyte concentration that is less than conventional ECM; and
Applying a smaller machining voltage than conventional ECM.
2. OPTIMIZATION
The study of metal cutting focuses mainly on the input work materials, properties and features of tools, and
machine parametric settings affecting output quality characteristics and process efficiency. A great improvement
in process efficiency can be achieved by process parametric optimization that determines and identifies the
regions of critical process control factors leading to responses or desired quality characteristics with acceptable
variations promising a lower cost of manufacturing. Selection of optimal machining condition(s) is the essential
factor in achieving this goal. In any advanced metal cutting operation, the manufacturer wants to set the process-
related controllable variable(s) at their optimal operating conditions with minimum variability in the output(s)
and effect of uncontrollable variables on the levels. To design and implement an effective process control for
metal cutting operation by parametric optimization, a manufacturer seeks to balance between cost and quality at
each stage of operation
Single Response Optimization
Taguchi method is a traditional approach for robust experimental design that seeks to obtain the best
combination set of factors/levels with the lowest societal cost solution to achieve customer requirements
(Jeyapaul et al., 2006; Biermann et al., 2013). Taguchi’s approach to design of experiments is easy to adopt and
apply for users with limited knowledge of statistics; hence it has gained a wide popularity in the engineering and
scientific community. In the Taguchi design method the design parameters (factors which can be controlled) and
noise factors (factors which cannot be controlled), which influence product quality, are considered. The main
thrust of the Taguchi technique is the use of parametric design, which is an engineering method for product or
process design that focuses on determining the parameter settings producing the best levels of quality
characteristic with minimum variations. Taguchi design provides a powerful and efficient method for designing
processes that operate consistently and optimally over a variety of conditions (Ghani et al., 2004; Prasad et al
2013).
Multi-Response Optimization
Grey-relational analysis (GRA) is a measurement technique, which focuses on the quantitative explanation and
comparison of variations. It quantifies all the effects of the various factors on response and their relations which
are called the whitening of factor relation. In grey theory, the black box is used to point out a system lacking
internal information. The black is indicating a lack of information but the white is full of information. Thus, the
information which is either incomplete or undetermined is called a grey. A system having incomplete
information is called grey system. The grey number in grey system represents a number with less complete
information. The grey element represents an element with incomplete information. The grey-relation is the
relation with incomplete information. GRA is a measurement technique in grey system theory that analyse the
degree of relationship in a discrete sequence (Deng, 1989, Lin et al., 2002, Jeyapaul et al., 2005; Tosun et al.,
2006).

3. RESEARCH DESIGN PROCESS
The solid modeling design package is utilized for configuring the design and sizing of the various parts of the
set-up. The modeling package was useful in analyzing various possible arrangements of the constituent systems
of the set-up by varying their sizes, models and placements.
A. Material selection
1. Structural Material
The literature survey shows that stainless steel has been used as a structural material for the set-up. Since
the set-up involves only light-weight components, as a cost-cutting measure mild steel is selected for structural
design of the supporting machine body. Mild steel has good toughness and an
adequate strength for fabricating the structural parts and to meet the service requirements of the set-up. The
parts made of mild steel are chromium-plated for aesthetic looks and corrosion resistance (mild steel has a
density of 7.85 gm/cm3 and contains 0.15 to 0.3 % carbon).
2. Electrical System Material
Fiber materials are used for the parts that come into contact with electrical system. It acts as a better
insulator.
3. Material for Electrochemical Service
Parts that come into contact with electrolyte require non-corrosive materials and hence acrylic material is
used in those places.
4. Sizing of Parts
Some of the dimensions have been set with reference to specifications found through literature survey. Other
dimensions have been calculated considering the compactness, functional movements of mating parts, working
conditions, arrangement constraints and space utilization as given below.
5. Chamber Size
The dimensions of the machine chamber is set at 200 x 100 x 80mm, which equals to a capacity of 1.6 liters (as
10 cm3 = 1 liter). Since the micro-tool and work-piece used are in the order of micron thickness, the volume of
electrolyte required to connect the gap between the electrodes is low (say 100 ml. and less).Hence, considering
all these factors along with human working constraints, the size of the chamber is fixed as the above.
6. Filter Tank
The tank has to house the filter and to receive the contaminated electrolyte from the chamber for filtering and re-
circulate it continuously into the chamber. Hence, it should store 3 to 4 times the quantity of electrolyte that
flows in the chamber during machining. On this basis, its capacity was
decided at 1.2 liters. (Tank dimensions are: 200 x 100 x 60 mm).
7. Main Screw Rod
Its dimensions are: 183 mm length, 12 mm dia. In the mid-portion a screw thread of 30 tpi (threads per inch) is
machined for 75 mm length to provide linear up and down movements to the tool-feeding device to a required
level in accordance with the depth of the chamber and work-piece
placement in it.
8. Angle Plate
The width of the angle plate is calculated (120 x 100 x 8 mm) to suit the diameter of stepper motor and its length
is calculated considering other parts that come into contact with it.
9. Base Plate
The base plate dimensions are calculated to accommodate all the parts that are to be placed on it. The base plate
is provided with four bushes at the bottom for easy handling.
10. Other Parts
The dimensions of other parts are calculated considering space arrangements and functional requirements of
the various parts in the total setup.
B. Integration of the system
The proposed design was modeled using the solid modeling software and the various parts were sized based on
the electrolyte tank capacity. The machine structure was also analyzed using the analysis software. Figure 1
shows the block diagram of EMM. The developed EMM set-up shown in Figure 1, comprising of the following
systems:

• Machine set-up structure;
• Tool electrode feed system;
• Inter-electrode gap control system;
• Electrolyte supply system;
• Microcontroller unit.
Figure 1: Block Diagram of EMM-setup
Figure 2: Electrochemical Micro Machining Setup
4. FABRICATION OF AMCs
Aluminum matrix composites (AMCs) offer superior combination of properties in such a manner that today
no existing monolithic material can rival. Over the years, AMCs have been tried and used in numerous
structural,non-structural and functional applications in different engineering sectors. In preparing metal matrix
composites by the stir casting method, there are several factors are considerable attention, including
The difficulty of achieving a uniform distribution of the reinforcement material;
Wettability between the two main substances;
Porosity in the cast metal matrix composites; and
Chemical reactions between the reinforcement material and the matrix alloy.1% magnesium are added
to the molten aluminum material to get good interface compatibility and to improve the interface
continuity during synthesis of Al/SiC composite (Pai et al 1995). The stir casting set-up is
shown in Figure 3

Figure 3: Stir casting setup
A. Aluminium 6061 alloy
The first two materials used in this investigation consist of 6061 aluminum alloy as matrix and its chemical
composition is shown in below Table 1
.
Table 1 :Chemical Composition of AL 6061
Component Cr Fe Cu Mn Mg Si Ti Zn Al others
Wt % 0.2
max
0.7
0.25 0.1 1 0.6
max
0.1
0.15
max
98.1 remaining
a) Fabrication of Al 6061 - 6 % wt of Gr metal matrix composite
The aluminum matrix was reinforced with 6 % wt of Gr.The average particle size Gr was 70 microns. The
composites were prepared through stir casting route as shown in Figure 4.1. The aluminum alloy was preheated
in a resistance furnace at 450º C for 2 hour before melting. Gr was also preheated in a resistance furnace at 1100º
C for 2 hour. The preheated aluminum were first heated above the liquidus temperature to melt them completely,
and then slightly cooled below the liquidus to maintain the slurry in the semi-solid state. This procedure has been
adopted while stir casting aluminum composites (Riaz Ahamed et al 2008). The preheated reinforcements were
added and mixed manually. Manual mixing was used because it was very difficult to mix using automatic device
when the alloy was in a semisolid state. The composite slurry was then reheated to a fully liquid state, and
mechanical mixing was carried out for about 20 min at an average mixing speed of 250 rpm. The final
temperature was controlled to be within 750°C±20°C, and pouring temperature was controlled to be around
700°C. After thorough stirring, the melt was poured into steel molds of size 100x100x10 mm and allowed to
cool to obtain cast sheet (Riaz Ahamed et al 2010). Then the thickness was reduced to 0.5 mm through rolling
and the same was cut in to 50 x 50 x 0.5 mm to accommodate into the EMM.
b) Fabrication OF Al 6061 - 5 % wt of SiC p – 5 % wt of Gr hybrid metal matrix composite
The aluminum matrix is reinforced with 5 % wt of SiC p / 5 % wt of Gr. The average particle size SiCp was 50
microns and Gr was 70 microns.The aluminum alloy was preheated in a resistance furnace at 450º C for 2 hour
before melting. SiCp and Gr were also preheated in a resistance furnace at 1200º C for 3 hour. The preheated
aluminum were first heated above th liquidus temperature to melt them completely, and then slightly cooled
below the liquidus to maintain the slurry in the semi-solid state. This procedure has been adopted while stir
casting aluminum composites (Riaz Ahamed et al 2008). The preheated reinforcements were added and mixed
manually.Manual mixing was used because it was very difficult to mix using automatic device when the alloy
was in a semi-solid state. The composite slurry was then reheated to a fully liquid state, and mechanical mixing
was carried out for about 20 min at an average mixing speed of 300 rpm. The final temperature was controlled to
be within 750°C ± 20°C, and pouring temperature was controlled to be around 700°C. After thorough stirring,
the melt was poured into steel molds of size 100x100x10 mm and allowed to cool to obtain cast sheet. Then the
thickness was reduced to 0.5 mm through rolling and the same was cut in to 50x50x0.5 mm used as work-piece
inEMM.
B. Aluminium 6063 alloy
Another three materials used in this investigation consists of 6063 aluminum alloy as matrix and its chemical
composition is shown in below Table 2.
Table 2 :Chemical Composition of Al 6063
Component Cr Fe Cu Mn Mg Si Ti Zn Al others
Wt % 0.2
max
0.7
0.25 0.1 1 0.6
max
0.1
0.15
max
98.1 remaining
a) Fabrication of Al 6063-10% wt of TiC metal matrix composite

The aluminum matrix was reinforced with 10 % wt of TiC.The average particle size TiC was 70 microns. The
aluminum alloy was preheated in a resistance furnace at 450º C for 2 hour before melting. TiC was also
preheated in a resistance furnace at 1450º C for 3 hour. The preheated
aluminum were first heated above the liquidus temperature to melt them completely, and then slightly cooled
below the liquidus to maintain the slurry in the semi-solid state. The preheated reinforcements were added and
mixed manually. Manual mixing was used because it was very difficult to mix using automatic device when the
alloy was in a semi-solid state. The composite slurry was then reheated to a fully liquid state, and mechanical
mixing was carried out for about 20 min at an average mixing speed of 250 rpm. The final temperature was
controlled to be within 750°C±20°C, and pouring temperature was controlled to be around 700°C. After
thorough stirring, the melt was poured into steel molds of size 100x100x10 mm and allowed to cool to obtain
cast sheet. Then the thickness was reduced to 0.5 mm through rolling and the same was cut in to 50x50x0.5 mm
to accommodate into the EMM.
b) Fabrication of Al 6063 -10 % wt of SiCp metal matrix composite
It is well suitable for high temperature application due their high thermal conductivity. The aluminum matrix
was reinforced with 10% wt of SiCp. The average particle size SiCp was 50 microns. The aluminum alloy was
preheated in a resistance furnace at 450o C for 2 hour before melting. Molten aluminum was stirred at (300
rpm.) to get suitable vortex. Later silicon carbide particles were added to molten metal. This process was
followed to modify reinforcement particles distribution through the molten aluminum. Due to the vortex effect,
silicon carbide particles were pulled inside the molten metal and uniformly distributed. Molten aluminum was
stirred for (1-5 min.) until the molten aluminum becomes slurry. Later molten aluminum was poured into
suitable stainless steel mould, which is preheated at 250°C to prevent sudden cooling for molten aluminum. This
process was repeated several times according to reinforcement particles ratio. It was noted obviously increasing
in slurry viscosity especially at 10 wt. % silicon carbide particles. This phenomenon requires long stirring time
to overcome the difficulties in casting process. SiCp was also preheated in a resistance furnace at 1200o C for 2
hour. The preheated aluminum were first heated above the liquidus temperature to melt them completely, and
then slightly cooled below the liquidus to maintain the slurry in the semisolid state. The preheated
reinforcements were added and mixed manually. Manual mixing was used because it was very difficult to mix
using automatic device when the alloy was in a semisolid state. The composite slurry was then reheated to a
fully liquid state, and mechanical mixing was carried out for about 15–20 min at an average mixing speed of 250
rpm. The final temperature was controlled to be within 750°C ± 20°C, and pouring temperature was controlled to
be around 720°C. After thorough stirring, the melt was poured into steel molds of size 100x100x10 mm and
allowed to cool to obtain cast sheet. Then the thickness was reduced to 0.5 mm through rolling and the same was
cut in to 50x50x0.5 mm to accommodate into the EMM.
c) Fabrication of Al-6063-10% wt of SiC- 5% wt of B4C hybrid metal matrix composite
The material used in this investigation consists of 6063 aluminum alloy as matrix and it is well suitable for high
temperature application due their high thermal conductivity. The aluminum matrix was reinforced with 10% wt
of SiC - 5% wt of B4C. The average particle size SiC was 50 microns
and B4C was 50 microns. The composites were prepared through stir casting route as shown in Figure 1. The
aluminum alloy was preheated in a resistance furnace at 450º C for 2 hour before melting. SiC and B4C were
also preheated in a resistance furnace at 1100º C for 2 hour. The preheated reinforcements were added and
mixed manually. Manual mixing was used because it was very difficult to mix using automatic device when the
alloy was in a semisolid state. The composite slurry was then reheated to a fully liquid state, and mechanical
mixing was carried out for about 20 min at an average mixing speed of 300 rpm. The final temperature was
controlled to be within 700°C±30°C, and pouring temperature was controlled to be around 700°C.After through
stirring, the melt was poured into steel molds of size 50x50x5mm and allowed to cool to obtain cast sheet. The
fabricated all five AMCs are cover for the following application areas like: piston ring, channels for micro
reactors, nozzle plate for ink-jet printer head, cylinder liner, connecting rod.
5. OPTIMIZATION OF MACHINING PARAMETERS USING TAGUCHI TECHNIQUE
The optimization of process parameters is the key step in the Taguchi method. Twenty seven experimental runs
(L27), based on the orthogonal array (OA) of Taguchi methods were carried out. The multiresponse optimization
of the process parameters, viz. MRR, Overcut was performed in making a micro-hole in the process of micro-
ECM of AMCs, each experiment being replicated twice. Machining time, over cut and MRR were noted for
every trial.

A single response optimization of machining parameters for the drilling of Al 6061- 6%Gr
The assignment process parameters with their levels indentified for this investigation . Based on Taguchi’s L27
OA, drilling experiments were conducted on EMM of Al 6061- Gr. The experimental results such as MRR and
overcut were gathered for each trial . S/N ratios were calculated for all the responses since the objective of this
work was the maximization of MRR and minimization of overcut.
Table3: Experimental results for L27 OA of Al 6061- Gr MMC
S/N ratio of MRR and overcut
Trial
No
E V F mg/min MRR
Overcu
t µ m
for
MRR
S/N
ratio
S/N
ratio
for
overcut
1 20 5 25 0.36 245.46 -8.874
-
47.7996
2 20 5 40 0.315 222.32 -10.03
-
46.9396
3 20 5 55 0.435 196.67 -7.23
-
45.8748
4 20 7 25 0.54 211.2 -5.352
-
46.4939
5 20 7 40 0.51 180.62 -5.849
-
45.1353
6 20 7 55 0.435 198.44 -7.23
-
45.9526
7 20 9 25 0.525 200.65 -5.597
-
46.0488
8 20 9 40 0.465 228 -6.651
-
47.1587
9 20 9 55 -7.851 224.86 -6.108
-
47.0382
10 25 5 25 0.405 184.4
-
45.3152
11 25 5 40 0.3 226.1 -10.46 -47.086
12 25 5 55 0.42 193.92 -7.535
-
45.7525
13 25 7 25 0.285 171 -10.9
-
44.6599
14 25 7 40 0.585 193.14 -4.657
-
45.7174
15 25 7 55 0.33 210.86 -9.63
-
46.4799
16 25 9 25 0.39 144.4 -8.179
-
43.1913
17 25 9 40 0.42 207 -7.535
-
46.3194
18 25 9 55 0.405 151.6 -7.851 -43.614
19 30 5 25 0.255 217.72 -11.87 -46.758
20 30 5 40 0.345 242 -9.244
-
47.6763

21 30 5 55 0.375 216.16 -8.519
-
46.6955
22 30 7 25 0.465 204 -6.651
-
46.1926
23 30 7 40 0.285 267.46 -10.9
-
48.5452
24 30 7 55 0.315 222.32 -10.03
-
46.9396
25 30 9 25 0.435 196.67 -7.23
-
45.8748
26 30 9 40 0.54 211.2 -5.352
-
46.4939
27 30 9 55 0.525 180.62 -5.597
-
45.1353
It can be seen that the optimal values for the maximum MRR were electrolyte concentration of 20 g/l, machining
voltage of 9 V and frequency of 55 Hz. The MRR increases with an increase in pulse frequency then the
dissolution efficiency increases rapidly, causing a rapid increment of MRR in the machining zone. Figure 6.3
shows the residual plot MRR. Table 4 shows the response table for S/N ratio of MRR. The interaction plot were
plotted to pictorially depict the interactions of the process parameters on MRR. In the full interaction plot, two
panels per pair of process parameters were shown in Figure 6.4. It shows that MRR is maximum in the
combination value of lower voltage, higher electrolyte concentration and higher frequency.
Table 4: Response table for MRR of drilling Al 6061-Gr
Signal to noise ratios (Larger is better)
Level
Electrolyte
concentration (E)
Voltage (V) Frequency ( F )
1 -6.992 -9.068 -8.056
2 -8.289 -7.912 -7.854
3 -8.378 -6.678 -7.748
Delta 1.386 2.39 0.348
Rank 2 1 3

a) Analysis for MRR of Drilling Al 6061- 6% Gr MMC
It can be seen that the optimal values for the maximum MRR were electrolyte concentration of 20 g/l, machining
voltage of 9 V and frequency of 55 Hz. The MRR increases with an increase in pulse frequency then the
dissolution efficiency increases rapidly, causing a rapid increment of MRR in the machining zone. The
interaction plot were plotted to pictorially depict the interactions of the process parameters on MRR. In the full
interaction plot, two panels per pair of process parameters. It shows that MRR is maximum in the combination
value of lower voltage, higher electrolyte concentration and higher frequency.
Table5:- Response table for overcut of drilling Al 6061- Gr MMC
Signal-to-noise ratios (Smaller-is-better)
Level
Electrolyte
concentration (E)
Voltage (V) Frequency ( F )
1 -46.49 -9.068 -45.80
2 -45.35 -7.912 -46.79
3 -46.70 -6.678 -45.94
Delta 1.35 1.00 0.97
Rank 1 2 3

B.Single response optimization of machining parameters for the drilling of Al 6061- 5% SiCp-
5%Gr
The assignment of factors with their levels identified for this investigation is given in Table 6.4. Based on
Taguchi’s L27 OA, drilling experiments were conducted on EMM of Al 6061-SiC-Gr. The experimental results
such as MRR and Overcut were gathered for each trial and it is shown
in Table 6.4. S/N ratios were calculated for all the responses since the objective of this work was the
maximization of MRR and the minimization of Overcut. Therefore, MRR is larger-is-better and for overcut,
smaller-is-better type was considered for the analysis.
Table 6:- Experimental results for L27 OA of Al 6061- SiCp-Gr MMC
S/N ratio of MRR and Overcut
Trial
No
V E F MRR mg/min Overcut µm
S/N
Ratio
for MRR
S/N Ratio
for
Overcut
1 6 20 30 0.19 212.46 -14.42 -46.55
2 6 20 40 0.218 167.32 -13.56 -44.47
3 6 20 50 0.3 141.67 -10.75 -43.03
4 6 25 30 0.374 156.2 -8.874 -43.87
5 6 25 40 0.354 125.62 -9.37 -41.98
6 6 25 50 0.3 143.44 -10.75 -43.13
7 6 30 30 0.364 145.65 -9.119 -43.27
8 6 30 40 0.31 173 -10.17 -44.76
9 6 30 50 0.343 169.86 -9.63 -44.6
10 8 20 30 0.281 129.4 -11.37 -42.24
11 8 20 40 0.208 171.1 -13.98 -44.67
12 8 20 50 0.291 138.92 -11.06 -42.86
13 8 25 30 0.198 116 -14.42 -41.29
14 8 25 40 0.406 138.14 -8.179 -42.81
15 8 25 50 0.229 155.86 -13.15 -43.85
16 8 30 30 0.374 89.4 -8.874 -39.03
17 8 30 40 0.280 152 -11.06 -43.64
18 8 30 50 0.270 76.6 -11.37 -37.68
19 10 20 30 0.177 162.72 -15.39 -44.23
20 10 20 40 0.239 187 -12.77 -45.44
21 10 20 50 0.218 161.16 -13.56 -44.15

22 10 25 30 0.322 149 -10.17 -43.46
23 10 25 40 0.198 212.46 -14.42 -46.55
24 10 25 50 0.218 167.32 -13.56 -44.47
25 10 30 30 0.302 141.67 -10.75 -43.03
26 10 30 40 0.374 156.2 -8.874 -43.87
27 10 30 50 0.354 125.62 -9.37 -41.98
a) Analysis for MRR of Drilling Al 6061- 5% SiCp-5% Gr MMC
It can be seen that the optimal values for the maximum MRR is the machining voltage of 6 V,electrolyte
concentration of 30 g/l and frequency of 40 Hz.. Table 7 shows the response table for S/N ratio of MRR. he
interaction plot has been plotted to pictorially depict the interactions process parameters on MRR.. It shows
that the MRR is maximum in the combination value of lower voltage, higher electrolyte concentration and
medium frequency.
Table7:-Response table for the MRR of drilling Al 6061- SiCp-Gr MMC
Signal-to-noise ratios (larger-is-better)
Level Voltage (V) Electrolyte concentration (E) Frequency (F)
1 -10.739 -12.984 -11.489
2 -11.496 -11.434 -11.375
3 -12.096 -9.913 -11.466
Delta 1.357 3.070 0.184
Rank 2 1 3
.

Table8:-Response table for overcut of drilling Al 6061- SiCp-Gr MMC
Signal-to-noise ratios (smaller-is-better)
Level
Voltage
(V)
Electrolyte concentration
(E)
Frequency
( F )
1 -43.96 -44.18 -43.00
2 -42.01 -43.49 -44.24
3 -44.13 -42.43 -42.86
Delta 2.12 1.75 1.38
Rank 1 2 3
The interaction plot was made to pictorially reflect the interactions of the process parameters on overcut. In the
full-interaction plot, two panels per pair of process parameters. It shows that overcut is maximum in the
combination value of medium voltage, higher electrolyte concentration and higher frequency.

C. Single response optimization of machining parameters for the drilling of Al 6063- 10% TiC
The assignment of factors with their levels identified for this investigation is given in Table 6.7. Based on
Taguchi’s L27 OA, drilling experiments were conducted on EMM of Al 6063- TiC. The experimental results
such as the MRR and the overcut were gathered for each trial
Table 9:-Experimental results for L27 OA of Al 6063- TiC MMC
S/N ratio of MRR and Overcut
Trial
No
V E F
mg/min
MRR
Overcut µ
m
S/N Ratio
for MRR
S/N Ratio for
Overcut
1 6 20 30 0.19 210.6 -14.4249 -46.5455
2 6 20 40 0.21 167.32 -13.5556 -44.471
3 6 20 50 0.29 141.67 -10.752 -43.0256
4 6 25 30 0.36 156.2 -8.87395 -43.8736
5 6 25 40 0.34 125.62 -9.37042 -41.9812
6 6 25 50 0.29 143.44 -10.752 -43.1334
7 6 30 30 0.35 145.65 -9.11864 -43.2662
8 6 30 40 0.32 173 -10.1728 -44.7609
9 6 30 50 0.33 169.86 -9.62972 -44.6018
10 8 20 30 0.27 129.4 -11.3727 -42.2387
11 8 20 40 0.2 171.1 -13.9794 -44.665
12 8 20 50 0.28 138.92 -11.0568 -42.8553
13 8 25 30 0.19 116 -14.4249 -41.2892
14 8 25 40 0.39 138.14 -8.17871 -42.8064
15 8 25 50 0.22 155.86 -13.1515 -43.8547
16 8 30 30 0.36 89.4 -8.87395 -39.0268
17 8 30 40 0.28 152 -11.0568 -43.6369
18 8 30 50 0.27 76.6 -11.3727 -37.6846
19 10 20 30 0.17 162.72 -15.391 -44.2288
20 10 20 40 0.23 187 -12.7654 -45.4368
21 10 20 50 0.21 161.16 -13.5556 -44.1451
22 10 25 30 0.31 149 -10.1728 -43.4637
23 10 25 40 0.29 109.5 -10.752 -40.7883
24 10 25 50 0.22 146 -13.1515 -43.2871
25 10 30 30 0.36 78.62 -8.87395 -37.9107

26 10 30 40 0.41 158.45 -7.74432 -43.9978
27 10 30 50 0.33 149.66 -9.62972 -43.5021
Therefore, for MRR, larger-is-better and for overcut smaller-Is better type category was considered for the
analysis. The S/N ratio for larger the-better type and smaller-the-better . The S/N ratio was computed using the
for each of the twenty-seven trial conditions for the MRR and Overcut and 6.15 shows the optical image for the
micro-hole of Al 6063- TiC MMC.
a) Analysis for the MRR of Drilling Al 6063- TiC MMC
It can be seen that the optimal values for the maximum MRR is a machining voltage of 6V,electrolyte
concentration of 30 g/l and a frequency of 40 Hz. The interaction plots were made to pictorially reflect the
interactions of the process parameters on MRR. It shows that MRR is maximum in the combination value of
lower voltage, higher electrolyte concentration and medium frequency.
Table 10 Response table for the MRR of drilling Al 6063- TiC
Level Voltage (V)
Electrolyte
concentration (E)
Frequency ( F )
1 -10.739 -12.984 -11.281
2 -11.496 -10.981 -10.842
3 -11.337 -9.608 -11.450
Delta 0.758 3.376 0.608
Rank 2 1 3

b) Analysis for Overcut of Drilling Al 6063- 10% TiC MMC
. It can be concluded that the optimal values for minimum overcut is machining voltage of 8 V, electrolyte
concentration of 30 g/l and frequency of 30 Hz. The interaction plot was made to pictorially reflect the
interactions of the process parameters on overcut. In the full interaction plot, two panels per pair of process
parameters shows that overcut is maximum in the combination value of medium voltage, higher electrolyte
concentration and lower frequency.
Table11:-Response table for the overcut of drilling Al 6063- TiC MMC
Level
Voltage
(V)
Electrolyte level concentration
(E)
Frequency ( F)
1 -43.96 -44.18 -42.43
2 -42.01 -42.72 -43.62
3 -42.97 -42.04 -42.90
Delta 1.96 2.14 1.19
Rank 2 1 3

D. Single response optimization of machining parameters for the drilling of Al 6063 - 10 % wt of SiC
p – 5 % wt of B4C
The assignments of process parameters with their levels identified for this investigation are given in Table 12.
Based on Taguchi’s L27 OA ,drilling experiments were conducted on the EMM of Al 6063-SiCp - B4C. The
experimental results such as MRR and overcut were gathered for each trial and it is shown in Table 6.13. S/N
ratios were calculated for all the responses since the objective of this work was the maximization of MRR and
minimization of overcut. Therefore, MRR, which is larger-is-better and overcut that, is smaller-is-better type
was considered for the analysis. The S/N ratio for large-is-better type.
Table 12 Experimental results for L27 OA of Al6063-SiCp – B4C MMC
S/N ratio of MRR and overcut
Trial
No
V E F mg/min MRR
Overcut µ
m
S/N ratio
forMRR
S/N ratio
for overcut
1 4 20 25 0.27 243 -11.373 -47.694
2 4 20 40 0.34 194 -9.370 -45.772
3 4 20 55 0.31 168 -10.173 -44.529
4 4 30 25 0.45 183 -6.936 -45.262
5 4 30 40 0.49 152 -6.196 -43.637
6 4 30 55 0.26 170 -11.701 -44.599
7 4 40 25 0.33 222 -9.630 -46.945
8 4 40 40 0.51 200 -5.849 -46.036
9 4 40 55 0.38 96 -8.404 -39.683
10 7 20 25 0.42 156 -7.535 -43.889
11 7 20 40 0.4 198 -7.959 -45.917
12 7 20 55 0.57 165 -4.883 -44.365
13 7 30 25 0.34 148 -9.370 -43.425
14 7 30 40 0.39 212 -8.179 -46.538

15 7 30 55 0.42 189 -7.535 -45.511
16 7 40 25 0.46 123 -6.745 -41.829
17 7 40 40 0.38 186 -8.404 -45.412
18 7 40 55 0.56 110 -5.036 -40.844
19 10 20 25 0.47 196 -6.558 -45.863
20 10 20 40 0.31 221 -10.173 -46.883
21 10 20 55 0.34 195 -9.370 -45.819
22 10 30 25 0.43 183 -7.331 -45.270
23 10 30 40 0.39 143 -8.179 -43.087
24 10 30 55 0.44 170 -7.131 -44.622
25 10 40 25 0.29 112 -10.752 -40.956
26 10 40 40 0.37 192 -8.636 -45.684
27 10 40 55 0.51 178 -5.849 -45.111
a) Analysis for MRR of Drilling Al6063-SiCp – B4C MMC
It can be seen that the optimal values for the maximum MRR is a machining voltage of 7 V, an electrolyte
concentration of 40 g/l and a frequency of 55 HzThe interaction plot was made pictorially reflect the interactions
of the process parameters on MRR. In the full-interaction plot, two panels per pair of process parameters. It
shows that the MRR is maximum in the combination value of medium voltage, higher electrolyte concentration
and higher frequency.
Table13:-Response table for the MRR of drilling Al 6063-SiCp – B4C MMC
Level Voltage (V)
Electrolyte
level concentration (E)
Frequency ( F )
1 -8.848 -8.599 -8.470
2 -7.294 -8.062 -8.105
3 -8.220 -7.701 -7.787
Delta 1.554 0.899 0.683
Rank 1 2 3

b) Analysis for Overcut of the Drilling Al6063-SiCp – B4C MMC
It can be concluded that the optimal values for a minimum overcut is a machining voltage of 7 V, an electrolyte
concentrations of 40 g/l and a frequency of 55Hz. The interaction plot was made to pictorially reflect the
interactions of the process parameters on overcut. In the full-interaction plot, two panels per pair of process
parameters were shown in Figure 6.30. It shows the overcut is maximum in the combination value of medium
voltage, higher electrolyte concentration and higher frequency.
Table14:- Response table for the overcut of drilling Al 6063-SiCp –B4C MMC
Level
Voltage
(V)
Electrolyte
level concentration (E)
Frequency
( F )
1 -44.90 -45.63 -44.56
2 -44.18 -44.66 -45.44
3 -44.80 -43.59 -43.88
Delta 0.72 2.04 1.56
Rank 3 1 2

6. RESULTS AND DISCUSSIONS
As the machining voltage is increased, the MRR also increased. The machining rate reaches its maximum value
at a particular voltage and decreased because electrode surface is gradually covered by bubbles generated at the
increased voltage values. With increase in the applied voltage, the machining current in the inter-electrode gap
(IEG) increases, this leads to the enhancement of MRR.
It is also observed that increase in electrolyte concentration increases the MRR gradually. With increasing the
electrolyte concentration, the electrical conductivity of the electrolyte increases and also that releases large
number of ions in IEG, which results in higher machining current in IEG and causes higher MRR, at the same
time the ions associated with the machining operation in the machining zone also increase. According to
Faraday’s law, the Material Removal Rate is proportional to the current density. Hence, the machining rate
increases with increase in electrolyte concentration. A higher concentration of ions reduces the localization
effect of electrochemical material removal reactions. This leads to higher overcut and thus reduces the
machining accuracy. Pulsating current has three parameters: pulse on-time, pulse offtime, and peak-current
density which can be varied independently to achieve desired machining rate. By suitable choice of the above
parameters, variations of electrolyte conductivity in the machining region could be reduced and high,
instantaneous mass transport achieved even at low electrolyte flow rates. The appropriate selection of length and
duty of pulse was essential to obtain the best surface quality. Experiments performed to study the effect of
variation in pulse on-time and pulse off-time on surface quality indicated that short pulse on-time and high pulse
offtime yield improved surface with less pitting .In the machining of AMCs on EMM for all the five cases, it

was observed that the Material Removal Rate decreased with an increase in frequency. At very high frequencies
the Material Removal Rate was very low and the duty cycle needed to be low so that the electrolyte had more
time to flush away the reaction products. It was observed that the MRR increased with increase of pulse on-time
which was in accordance with the results obtained as the MRR decreased at higher frequencies. Based on the
results obtained from the various methodologies, the frequency does not much impact on the output responses.
A.Single-response optimization for drilling AMCs
Optimization of the single-response problem using Taguchi method provides an effective
methodology for optimization of EMM parameters. The single response optimization of the
S/N ratio for MRR and overcut on different AMCs was obtained by Taguchi analysis.. Based
on delta value, the rank showed that voltage and electrolyte concentration have stronger effects
on both MRR and overcut.
B. Multi-response optimization for drilling AMCs
Multi-response optimization was performed for all five different AMCs using the grey-relational analysis. Based
on the ANOVA table, it shows that voltage and electrolyte concentration have stronger effects on both MRR and
overcut.
7. CONCLUSION
The following are the outcomes of this research work conducted with the objective of minimization of overcut
and maximization of MRR:
1. An EMM machine set-up was modelled using solid modelling software and the various parts were designed
based on the requirements. Finally EMM setup is developed. The developed EMM machine set-up
comprises of the following systems.
• Machine set-up structure
• Tool electrode feed system
• IEG control system
•Electrolyte supply system; and
• Microcontroller unit.An EMM machine set-up for the application of micro-hole drilling with a resolution of 4
µm has been developed with the capability of maintaining the set Inner-electrode gap (IEG)
2. The machining rate as well as overcut increases with the increase in machining voltage and electrolyte
concentration.
3. The most effective range for electrolyte concentration was 24-30 g/l, for voltage, it was 7 – 9 V and for
frequency, it was 25 -55 Hz for a moderate machining speed and lower overcut.
4. Optimization of the single-response problem using Taguchi method provided an effective methodology for the
design optimization of EMM parameters on Al 6061 - 6% wt of Gr scomposites. The following can be
concluded
• The optimal values for maximum MRR was electrolyte concentration of 20 g/l, machining voltage of 9 V and
frequency of 55 Hz and the optimal values for minimum overcut is electrolyte concentration of 25 g/l, machining
voltage of 9 V and a frequency of 25 Hz.
.• Based on the Confirmatory test, the improvements of the MRR from the initial machining parameters to the
optimal machining parameters are about 37.5 % and overcut, it is about 41.2 %.
• Voltage and electrolyte concentration were the most significant factor that influences the MRR and overcut.
design optimization of EMM parameters on Al 6061- 5 % wt of SiCp
- 5% wt of Gr composites. The following can be concluded:

• The optimal values for maximum MRR was a machining voltage of 6 V, an electrolyte concentration of 30 g/l
,and a frequency of 40 Hz and the optimal values for minimum overcut was a machining voltage of 8 V, an
electrolyte concentration of 30 g/l and a frequency of 50Hz
.• Based on the Confirmatory test, the improvements of the MRR from the initial machining parameters to the
optimal machining parameters are about 63.15 % and for the overcut, it is about 63.95 %.
• Voltage and electrolyte concentration were the most significant factor that influence the MRR and Overcut.
design optimization of EMM parameters on Al 6063 - 10% wt of TiCcomposites. The following can be
concluded:
• The optimal values for maximum MRR was 6 V, an electrolyte concentration of 30 g/l and a frequency of 40
Hz and the optimal values for minimum overcut was a machining voltage of 8 V, an electrolyte concentration of
30 g/l and a frequency of 30 Hz.
• Based on the confirmatory test, the improvements of the MRR from the initial machining parameters to the
optimal machining parameters are about 68.5 % and for overcut, it was about 57.5 %.
• Voltage and electrolyte concentration were the most significant factor that influence the MRR and overcut.
design optimization of EMM parameters on Al 6063- 10 % wt of SiCp
composites. The following can be concluded:
• The optimal values for maximum MRR was a machining voltage of 7 V, an electrolyte concentration of 24 g/l
and a frequency of 50 Hz and the optimal values for minimum overcut is machining voltage of 9 V, an
electrolyte concentration of 18 g/l, and a frequency of 50Hz.
optimal machining parameters are about 69.69 % and for overcut, it is about 62.30 %.
• Voltage, electrolyte concentrations are the most significant factor that influence the MRR and frequency,
voltage are the most significant factor that influence the overcut.
design optimization of EMM parameters on Al 6063- 10 % wt of SiCp–5 % of B4C composites. The following
can be concluded:
• The optimal values for maximum MRR and overcut were machining voltage of 7 V, an electrolyte
concentration of 40 g/l and a frequency of 55 Hz.
optimal machining parameters are about 107.4 % and overcut was about 54.73 %
.• Voltage, electrolyte concentrations are the most significant factor that influences the MRR and frequency,
electrolyte concentration are the most significant factor that influences the overcut.
9. From the study of result in EMM of Al-6061 / 6 % wt of Gr metal matrix composites using Taguchi
methodology and grey relational analysis, the following can be concluded:
• Based on the confirmatory test, improvements in Material Removal Rate and overcut were 08.33 % and 41.17
% respectively.
A. Scope for the further work
By adopting the analysis made in this thesis, this research can be extended with increased number of signal and
noise factors an increased levels for obtaining comparatively better results
.The present EMM machine set-up provides linear micro-tool movement vertically in the Z-direction
only. It can be further developed in future to provide linear movements in x, y directions also the need to
fabricate 3D micro-structures arises
.The investigation of EMM process can be carried out by including the flow rate, vibrating electrode,
rotating electrode and utilizing ultra-short pulsed power supply. It is assumed that the ultrasonic
vibrations would enhance the rate at which the reaction products are flushed out of the machining zone,
resulting in a higher Material Removal Rate. The pulsed laser would heat-up the machining zone locally,
increasing the rateof anodic dissolution

. Further experimental studies, especially micro structural analysis can be carried out in order to
understand the material structural change in the machined zone.
This research can be extended for other machining process.
Uncontrollable disturbing factors considered for the prediction of objectives. Mechanical properties of
the AMCs are to be considered in further research.
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