Improving quartz micro-machining performance by magnetohydrodynamic and zinc-coated assisted traveling wire-electrochemical discharge machining process

Publication date: Available online 17 January 2020Source: Materials Today: ProceedingsAuthor(s): Ankit D. Oza, Abhishek Kumar, Vishvesh BadhekaAbstractIn this industrial revolution era, machining of advanced non-conducting material like quartz is difficult and costly with existing conventional machining processes. Further its high hardness, brittleness and non-conducting nature add-up to machining difficulties. Traveling Wire-electrochemical discharge machining (TW-ECDM) process has a good potential of machining of quartz material. TW-ECDM process is a hybrid and complex combination of electrochemical machining (ECM) and wire-electrical discharge (W-EDM) machining process. However, due to poor electrolysis process, sparking phenomenon is not steady and uniform at higher machining depth. In the present work, the authors have tried to investigate the feasibility of Magnetohydrodynamic (MHD) assisted TW-ECDM process for machining of quartz. This MHD approach produces the magnetic field which helps to improve the electrolysis process, accuracy, and efficiency. Also, first-time zinc-coated brass wire of diameter 0.15 mm has been used to improve the machining performance. A hybrid approach of Taguchi robust design and ANOVA was used to analyze the process performance. Experimental results reveal that the MHD approach enhances the material removal rate (MRR) and reduces the surface rousghness (Ra) as compared to without MHD approach. The improvement in MRR was found from 25.35% to...
Source: Materials Today: Proceedings - Category: Materials Science Source Type: research