This document discusses electrochemical discharge machining (ECDM), which combines electrochemical machining (ECM) and electric discharge machining (EDM) to machine hard and brittle non-conductive materials like glass, quartz, and ceramics. It provides an introduction to ECDM, describes the working principle involving thermal and chemical material removal, lists the main subsystems of an ECDM setup, and compares ECDM to ECM and EDM in terms of material removal rate, accuracy, surface finish, and other factors. Key application areas of ECDM include micro-holes, grooves, and complex shapes in non-conductive materials for industries like turbines, filters, electronics, and
electrochemical discharge machining.
also known as electrochemical spark machining.
we covert normal drilling machine in electrochemical spark machining and perform drilling operation on the work piece and create a macrohole in a quartz glass. the results are shown in the ppt.
we created this project under the head of department of mechanical engineering ER. Rakesh sigh sir and ER.mudit tyagi sir from mtech department from noida institute of engineering and technology, greater noida.
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
unsatisfactory or uneconomical:
– Workpiece material is too hard, strong, or tough.
– Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
– Part shape is very complex with internal or external profiles
or small holes.
– Requirements for surface finish and tolerances are very high.
– Temperature rise or residual stresses are undesirable or
unacceptable.
So to eliminate this disadvantages non conventional machines can be used
UNCONVENTIONAL MACHINING PROCESS CLASSIFICATION-MECHANICAL ENERGY METHODS-ELECTRICAL ENERGY METHODS-CHEMICAL ENERGY METHODS-ELECTRO CHEMICAL ENERGY METHODS-THERMALENERGY METHODS.
electrochemical discharge machining.
also known as electrochemical spark machining.
we covert normal drilling machine in electrochemical spark machining and perform drilling operation on the work piece and create a macrohole in a quartz glass. the results are shown in the ppt.
we created this project under the head of department of mechanical engineering ER. Rakesh sigh sir and ER.mudit tyagi sir from mtech department from noida institute of engineering and technology, greater noida.
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
unsatisfactory or uneconomical:
– Workpiece material is too hard, strong, or tough.
– Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
– Part shape is very complex with internal or external profiles
or small holes.
– Requirements for surface finish and tolerances are very high.
– Temperature rise or residual stresses are undesirable or
unacceptable.
So to eliminate this disadvantages non conventional machines can be used
UNCONVENTIONAL MACHINING PROCESS CLASSIFICATION-MECHANICAL ENERGY METHODS-ELECTRICAL ENERGY METHODS-CHEMICAL ENERGY METHODS-ELECTRO CHEMICAL ENERGY METHODS-THERMALENERGY METHODS.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
Study of different work materials effect on surface roughness in electrochemi...eSAT Journals
Abstract In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter-electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is found to be most prominent on Brass work-piece.
Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass; Aluminium; Taguchi; ANOVA.
An **unconventional machining process** (or **non-traditional machining process**) is a special type of **machining process**in which there is no direct contact between the tool and the workpiece
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected tht
rough rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
1. Presented by;
MURLI SHESHERAO KUMBHARKAR
141413003
T.Y Production ( S/W)
Mr. S.U. GHUNAGE
Guide,
Assistant Professor
Production Engineering & Industrial
Management Department
College of Engineering Pune.
STUDY OF DISCHARGE MECHANISM IN
ELECTROCHEMICAL DISCHARGE
MACHINING PROCESS
2. Contents:-
Introduction
Need of ECDM
Working Principle of ECDM
Material Removal Mechanism in ECDM
Experimental setup of ECDM
Main Subsystem of ECDM
Main Influencing parameters
Advantages over ECM/EDM
Disadvantages over EDM/ECM
Application of ECDM
Comparison between ECDM, EDM and ECM
References
3. Introduction:-
• Electrochemical discharge machining is the combination of
Electric discharge machining (EDM) and Electrochemical
machining (ECM) process.
• Electrochemical Discharge Machining (ECDM) process is
mostly applied for micro-machining and scribing hard and
brittle, non-conducting materials like glass, quartz, ceramics
etc.
• The work first on the Electrode effect, anode or cathode effects
reported by Fizeau and his group of researchers and Foucault
and his co-researchers in 1844.
4. Introduction:-
• It was introduced in 1968 as electro discharge drilling by
Karafuji and Suda.
• It knows different name such as :
ESCM – Electro Chemical Spark Machining ( by V.K. Jain
et al.)
SACE – Spark Assisted Chemical Engraving ( by Fascio et
al.)
ECAM – Electro Chemical Anode Machining ( by Kubota)
DMNC – Discharge Machining of Non-Conductors ( by
Cook et al. )
SAE – Spark Assisted Etching ( by Daridon et al. )
5. Need of ECDM :
1. High Accuracy and Surface Finish
2. High Strength Alloys
3. Complex Surfaces
4. Technology Advancement
5. Machining on non-conducting materials
.
6. • The working principle in
ECDM is by combination
of thermal and chemical
mechanisms.
• When a high potential
difference is applied
between the two electrodes
( tool and work piece )
which are kept a few
microns apart gas bubbles
start forming continuously
at both the electrodes.
Working Principle of ECDM :-
7. Material Removal Mechanism in ECDM :-
MRR Mechanism
Thermal mode
Melting Vaporization
Chemical mode
Etching
9. • Machine Setup : Usually
it is a table top fabricated
machine or a specialized
set-up comprising of all
the necessary features.
• Power supply : consisting
of AC to DC converter
and Voltage modulator or
pulsed modulator.
• Control system : Consists
of micro-controller or
servo operated subsystem
to provide flexibility to
tool or work piece.
Main Subsystem of ECDM :-
10. Main Influencing parameters :-
Electrolyte Concentration
Voltage
Gas Film
Spark Generation
Tool Electrode
Auxiliary Electrode
11. Advantages over ECM/EDM :-
• The surface obtained have better finish than EDM and
ECM.
• Suitable for non-conducting materials.
• High accuracy.
• Methods does not leave any chips or burrs.
• Less power consumption.
• Set-up is not costly and can be developed or fabricated
on exiting facility through modification and attachments.
12. Disadvantages over EDM/ECM:-
• Chances to electrode wear.
• Initial cost of is high.
• Thickness of ceramic material can be
machined is limited to 1.5 mm.
• Radial overcut.
13. Application of ECDM :-
ECDM is novel hybrid micro-machining
technology for production of :
• Through and blind micro-holes
• Micro-grooves
• Micro-slots
• Micro-channels and Complex shapes
produced in non-conducting materials (
quartz, glass, and ceramics) etc.
14. • Miniature features of turbine blades ( micro-
turbulated cooling holes )
• Filters for food and textiles industries
• Micro-electro seam welding for copper plate
• Industrial applications like bearings, computer
parts, artificial joints, cutting tools, electrical
and thermal insulators etc.
• Trueing and Dressing of grinding wheels.
Application of ECDM :-
15. Comparison between ECDM, EDM and ECM
ASPECTS ECM EDM ECDM
PRINCIPLE Anodic dissolution Spark erosion Both
POWER 10,000A,2-3V,DC 200A,50-200V,DC 3-4A,40V,DC
WORK
PIECE
Conductive Conductive Conductive &
non- conductive
MRR Less Less 5times faster
than EDM
TOOL
WEAR
Less than both Higher than ECDM Less than EDM
ACCURAC
Y
Higher than EDM Dimensional
accurate :+-.03mm
+-.01mm
SURFACE
FINISH
Higher than both Less Higher than
EDM
COST Less initial than
ECDM
Less initial than
ECDM
High
16. 1) S.K Hajra Choudhury, A.K Hajra Choudhury “Workshop technology” Volume:2
machine tools, Media promoters and publishers pvt. ltd. Thirteenth edition (2010)
pp.605-650.
2) Amitabha Ghosh “Electrochemical Discharge Machining: Principle and
Possibilities” Sadhana Vol.22, Part 3, 1997,pp. 435-447. @ Printed India.
3) B. Doloi, B. Bhattacharyya and S.K. Sorkhel “ Electrochemical Discharge
Machining of Non-Conducting Ceramics ” DEF SCI J, Vol49, No 4, August 1999,
pp.331-338@1999, DESIDOC.
4) Indrajit Basak, Amitabha Ghosh “Mechanism of material removal in
electrochemical discharge machining: a theoretical model and experimental
verification” Journal of Materials Processing Technology 71 (1997) 350-359.
5) Anjali V. Kulkarni “Electrochemical Discharge Machining Process” DEF SCI
J, VOL. 57, NO.5, September2007.
6) Anjali. Kulkarni, R. Sharan, G.K. Lal “Experimental study of discharge
mechanism in electrochemical discharge machining” International Journal of
machine tool & Manufacturer 42 (2002) 1121-1127.
References
Editor's Notes
Glass also has the distinction of being transparent and having low electrical as well as thermal conductivity. It is increasingly being used in micro fabricated devices like solid oxide fuel cells, pumps, and reactors. The existing micromachining technologies for glass such as laser machining, ultrasonic machining, abrasive machining , and chemical etching techniques have certain undesirable effects and limitations