Abstract
Electro-chemical machining is practiced in aerospace, automobile and other heavy industries for shaping, milling, deburring and finishing operations. Application of ECM in micro fabrication and in the processing of thin films is referred to as electro-chemical micro machining (EMM). A variety of metals and alloys including conducting ceramics and highly corrosion-resistant alloys can be machined by EMM. EMM is now receiving considerable attention in the electronics and other high-tech industries, particularly as an alternate, “greener” method of processing metallic parts. Accumulation of reaction products in solution and depletion of bath components are of little concern in EMM, thus making it a simpler and environment friendly manufacturing process. EMM is based on controlled anodic electro-chemical dissolution process of the work piece with the tool as the cathode in an electrolytic cell. The performance of modern jet engine components such as turbine rotor and stator assemblies depends on a very large number of small holes. These high temperature components are difficult-to-machine, such as super alloys Alpha-Beta Titanium. The present work is, therefore, initiated to investigate the influence of various electro-chemical micro machining process parameters such as applied voltage, electrolyte concentration, micro-tool feed rate and duty cycle on the metal removal rate (MRR) and shape accuracy to fulfill the effective utilization of electro-chemical micromachining of Alpha-Beta Titanium. The main effect plots and micro-graph have been generated to study the effect of process parameters in electrochemical micromachining process.
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