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Effect of Over Voltage On Material Removal Rate
Effect of Over Voltage On Material Removal Rate
23-28 (2005)
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Abstract
Material removal rate in electrochemical machining is analyzed in context of over voltage and
conductivity of the electrolyte solution. It is observed that over voltage is very sensitive to equilibrium
gap and tool feed rate. Material removal rate decreases due to increase in over voltage and decrease in
current efficiency, which is directly related to the conductivity of the electrolyte solution. It is observed
that the corrected current density is always lower than the actual current. The calculated material
removal rate efficiency is found to be 57%.
Key Words: Electrochemical Machining, Over-voltage, Material Removal Rate, Conductivity
1. Introduction
Advanced materials are known for their improved
strength, thermal resistance, wear resistance and corrosion
resistance, which are machined by non-conventional energy sources. Among several non-conventional processes
[1-4] electrochemical machining is interesting because
the removal of material is by an atom to an atom resulting
in higher finish with stressed crack free surface and independent of the hardness of the work materials. Advance
manufacturing technology has evolved thrust areas like
automation of manufacture with high precession[5-7].
Recently, the product size ranging from 50 to 500 mm have
been prepared by Micro-electrochemical machining
and Micro-electrochemical Grinding [8-11]. Electrochemical Machining (ECM) is good for steel and super alloys
and most often used when machining either shaped holes
or cavities into electrically conductive materials [12,13].
At high concentration of electrolyte, electrolytes do not
behave ideally and resistance of the solution [14] increases which may cause deviation from Faradays law
and Ohms law. Further, it has been assumed that the pro*Corresponding author. E-mail: pk_srivastavapk@sancharnet.in
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S. K. Mukherjee et al.
Equilibrium gap
(cm)
Penetration rate
(cm/sec)
0.0025
0.0050
0.0075
0.0100
0.0150
0.0100
0.0058
0.0038
0.0030
0.0017
V - rZ F
Ye f
KA
(1)
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Figure 1. Variation of over-voltage with equilibrium machining gap when tool feed rate (f) = 0.00167 cm/sec, V
= 10 V, K = 0.2 ohm-1 cm-1, F = 96500, Z = 2, A =
55.85, r = 7.86, Ye are taken from Table 1.
Figure 3. Variation of over-voltage with equilibrium Machining gap. When tool feed rate (f) is varied as
equilibrium machining gap. Other data are same as
in Figure 1.
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S. K. Mukherjee et al.
(2)
are shown in Figure 8. The efficiency (h) of material removal calculated by Eq. 4,
h=
MRRc
100
MRRth
(4)
indicate that efficiency is about 57%. However the efficiency of maximum material removal is about 72% at
optimum condition [15,16]. It appears that this discrepancy in the material removal rate is due to de-
(3)
Figure 4. Variation of current density with equilibrium machining gap. When tool feed rate (f) varies as equilibrium machining gap, other data are same as in Figure
1, (a) for actual current density (b) for corrected current density.
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References
Figure 8. Material removal rate, (a) theoretical, (b) experimental, determined by Eq. (3).
3. Conclusion
The over-voltage is the important parameter which
restrict the material removal rate and is sensitive to tool
feed rate and equilibrium machining gap. If over voltage
DV = 0, then Eq. (1) reduces to
K = 345.57 Yef
This indicates that for maximum efficiency specific
conductance must be equal to 345.57 Yef. Increase in
over-voltage is associated with decrease in equivalent
conductance from its value at infinite dilution due to decrease in ionic mobility which depends on dielectric constant, viscosity and temperature of the electrolyte solution.
Further, researches are underway to test these models by taking the values of appropriate parameters and to
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