AN EXPERIMENTAL STUDY OF ELECTRO CEMICAL MICRO-

MACHINING ON SS316L USING NATURAL ELECTROLYTE WITH

REDUCED COPPER SUSPENDED PARTICLE

Guided by:
KALAIMEGAM M.E
Assistant Professor

Submitted by:
MUHAMED MISHAB K N (161081073)
MUHAMMAD BASIL AZEEZ P (161081074)
MUHAMMED NABEEL A P(161081075)
MUHAMMMED SHAFI E (161081076)
 ECMM AN INTRODUCTION
 ECMM produces smaller size components in high precision.
 ECMM promising technology offers,

ECMM on SS316
 Higher machining rate
 Better precision and control
 Machining wide range of materials
 Cost effective
 Environmental friendly.
 ECMM process:
Electrolyte
+++++
Work piece + + + + + + +
(Anode)
Micro tool
Electrical Energy (Cathode) 2
OVERVIEW OF ECMM
Contact Less electro chemical
forming process
Electrical Energy produces

ECMM on SS316
chemical reaction
Works on the principle of
Faraday’s Law

Faraday’s law states that the amount

of any substance deposited or
liberated during electrolysis is
proportional to the quantity of electric
charge passed and to the equivalent
weight of the substance.

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 OBJECTIVE OF THE PROJECT
 To study the influence of ECMM process parameters- Stainless Steel 316
by using natural electrolyte of Oxalic acid
 Electrolyte concentration

ECMM on SS316
 Machining voltage

 Machining current

 Duty cycle

 Frequency on MRR

 Further, design of experiments employing Taguchi’s Technique, ANOVA

and Genetic Algorithms are used to optimize the process parameters.

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OUTLINE OF THE PROJECT

ECMM on SS316
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SELECTION OF MATERIAL- SS316

 Stainless steel 316 - extensively used in heavy gauge

welded components.

ECMM on SS316
 Standard molybdenum
 Improved corrosion resistance.
 Improved machinability
 Outstanding welding characteristics
 Applied in,

 1. Food processing equipment

 2. Brewery equipment
 3. Chemical and petrochemical equipment
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 4. Laboratory benches & equipment…etc
SELECTION OF AN ELECTROLYTE
- OXALIC ACID
 Oxalic acid C2H2O4
 Colorless crystalline

ECMM on SS316
 Condensed formula HOOCCOOH
 Acid strength is much greater than that of acetic acid.

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 Innovative idea - Cost effective and Eco friendly
 EXPERIMENTAL
INVESTIGATION OF ECMM

ECMM on SS316
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EXPERIMENTAL INVESTIGATION
OF ECMM(CONT)

ECMM on SS316
The experiment is mainly conducted in two steps.
 Step 1:
 Note down initial weight of the work piece
 Test bed set up of work piece and SS tool
 Step 2:
 Note down final weight of the work piece
 Machining the work piece with change the parameter of voltage, duty
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cycle and electrolyte concentration
 Note down whole process the machining time
EXPERIMENTAL INVESTIGATION
OF ECMM(CONT)
Experimental Tabulation:

ECMM on SS316
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 ANALYSIS
OPTICAL MICROSCOPIC TEST
Analyzing the machined holes on SS316 -oxalic acid -Optical microscopic test.

ECMM on SS316
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SCANNING ELECTRON MICROSCOPIC
TEST

ECMM on SS316
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 ANALYSIS OF
OPT – SEM TEST RESULTS
Discussion on better voltage with fixed value of duty cycle &
concentration
Voltage-9v, Duty cycle 85 & Concentration 80g/liter

ECMM on SS316
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 ANALYSIS OF
OPT – SEM TEST RESULTS(CONT)
Discussion on better duty cycle with fixed value of voltage &
concentration
Duty cycle 25, Voltage 11v & Concentration 80g/liter

ECMM on SS316
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 ANALYSIS OF
OPT – SEM TEST RESULTS(CONT)
Discussion on better duty cycle with fixed value of voltage &
concentration
Duty cycle 70, Voltage 11v & Concentration 80g/liter

ECMM on SS316
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 ANALYSIS OF
OPT – SEM TEST RESULTS(CONT)
Discussion on better concentration with fixed value of voltage
& duty cycle
Concentration 40 g/liter, Voltage 11v & Duty cycle 85

ECMM on SS316
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 ANALYSIS OF
OPT – SEM TEST RESULTS(CONT)
Discussion on better concentration with fixed value of voltage
& duty cycle
Concentration 50 g/liter, Voltage 11v & Duty cycle 85

ECMM on SS316
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EXPERIMENTAL INVESTIGATION
OF ECMM(CONT)
Sampling Calculation for first run

MRR is calculated as given by the following formula:

ECMM on SS316
MRR = initial weight – final weight / density * total time

MRR = 8.434 – 8.431 / 0.0077 * 16.25

MRR = 0.0239 mm3/ min

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 COST EFFICIENT

Though we use natural electrolyte it reduces 40% of Total cost compare to other acids,

ECMM on SS316
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RESULTS AND DISCUSSIONS

ECMM on SS316
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RESULTS AND DISCUSSIONS(CONT)

ECMM on SS316
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RESULTS AND DISCUSSIONS(CONT)

ECMM on SS316
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 C ONCLUSION
The experimentation controls and allow to vary the below process
parameters on MRR according to need.
 Machining voltage
 Feed

ECMM on SS316
 Current
 Electrolyte

The experimentation work and analysis helps in finding the appropriate

parameters by varying the voltage, duty cycle and electrolyte
concentration the five observations are improving the machining process
parameters using natural electrolyte of oxalic acid with SS316 material

Also this experimentation

Green house machining could not affect the environment
Improve machining speed 23

Good performance especially in micro drilling.

Cost efficient
ECMM on SS316
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THANK YOU