Influence of Variant Electrolyte in Electrochemical Micromachining of Micro Holes in SMA Using Taguchi Optimization

B. Mouliprasanth B. Mouliprasanth , P. Hariharan P. Hariharan
Российский электрохимический журнал
Abstract / Full Text

Electrochemical micromachining (ECMM) is one of the commercially successful modern machining processes used in various manufacturing industries. Nitinol, a shape memory alloy (SMA) material used as micro and nano component in bio medical fields is difficult to machine using traditional methods due to its super elasticity and shape memory effect. This problem induced in studying the machining characteristics of NiTi alloy using ECMM Process. In this work, an effort is taken to produce micro holes in SMA—NiTi alloy of 0.25 mm thickness using variant electrolytes such as the passivating electrolyte (PE) and the non-passivating electrolyte (NPE) to study the machining characteristics. The variable input parameters considered are voltage, duty cycle and feed rate to study their effect on performance characteristics such as MRR, overcut, circularity and conicity. This study resulted in finding the suitable and optimized parameters for machining Nitinol with PE and NPE with better precision and good surface integrity. Optimization studies are also carried out by Taguchi method using minitab statistical software.

Author information
  • Research Scholar, Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, India

    B. Mouliprasanth

  • Professor, Department of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai, India

    P. Hariharan

  1. Bhattacharyya, B., Malapati, M., and Munda, J., Experimental study on electrochemical micromachining, J. Mater. Process. Technol., 2005, vol. 169, p. 485.
  2. Zhi-Wen Fan, Lih-Wu Hourng, and Ming-Yuan Lin, Experimental investigation on the influence of electrochemical micro-drilling by short pulsed voltage, Int. J. Adv. Manuf. Technol., 2011, vol. 61, p. 957.
  3. Sekar, T. and Marappan, R., Experimental investigations into the influencing parameters of electrochemical machining of AISI 202, J. Adv. Manuf. Syst., 2008, vol. 7, no. 2, p. 337.
  4. Hasan Demirtas, Oguzhan Yilmaz, and Bahattin Kanber, Experimental investigation of the effects of dedicated electrochemical machining parameters on freeform surface machining, J. Manuf. Processes, 2019, vol. 43, p. 244.
  5. Seung-geon choi, Seong-hyun kim, Xiong-jie cui, and Eun-sang lee, A study on electrochemical machining performance analysis of shape memory alloy with electrolyte and electrode, Proc. 65th IASTEM Int. Conf., Los Angeles, July 2017.
  6. Lotfi, A.A. and Daneshmand, S., The effect of operational cutting parameters on Nitinol-60 in wire electrodischarge machining, J. Adv. Mater. Sci. Eng., 2013, no. 4. https://doi.org/10.1155/2013/457186
  7. Kohl, M., Allen, D.M., Chen, T.T., Miyazaki, S. and Schworer, M., Anisotropy in micro devices produced by micromachining of cold-rolled NiTi sheets, Mater. Sci. Eng. A, 1999, vol. 270, no. 2, p. 145.
  8. Yang, I., Park, M.S., and Chu, C.N., Micro ECM with ultrasonic vibrations using a semi-cylindrical tool, Int. J. Prec. Eng. Manuf., 2009, vol. 10, no. 2, p. 5.
  9. Mouliprasanth, B. and Hariharan, P., Measurement of performance and geometrical features in electrochemical micromachining of SS304 alloy, Exp. Tech., 2019, vol. 44, p. 259. https://doi.org/10.1007/s40799-019-00350-y
  10. Eun-Sang Lee, Tae-Hee Shin, Baek-Kyoum Kim, and Seung-Yub Baek, Investigation of short pulse electrochemical machining for groove process on Ni-Ti shape memory alloy, Int. J. Precis. Eng. Manuf., 2010, vol. 11, no. 1, p. 113. https://doi.org/10.1007/s12541-010-0014-3
  11. Eun Sang Lee and Tae Hee Shin, An evaluation of the machinability of nitinol shape memory alloy by electrochemical polishing, J. Mech. Sci. Technol., 2011, vol. 25, no. 4, p. 963. https://doi.org/10.1007/s12206-011-0209-2
  12. Esmail Abedi, Saeed Daneshmand, Ali Akbar Lotfi Neyestanak, and Vahid Monfared, Analysis and modeling of electro discharge machining input parameters of nitinol shape memory alloy by de-ionized water and copper tools, Int. J. Electrochem. Sci., 2014, vol. 9, p. 2934.
  13. Li Long and Baoji, M.A., Effect of magnetic field on anodic dissolution in electrochemical machining, Int. J. Adv. Manuf. Technol., 2018, vol. 94, p. 1177. https://doi.org/10.1007/s00170-017-0983-9
  14. Anup Malik and Alakesh Manna, Investigation on the laser-assisted jet electrochemical machining process for improvement in machining performance, Int. J. Adv. Manuf. Technol., 2018, vol. 96, p. 3917. https://doi.org/10.1007/s00170-018-1846-8
  15. Sadagopan, P. and Mouliprasanth, B., Investigation on the influence of different types of dielectrics in electrical discharge machining, Int. J. Adv. Manuf. Technol., 2017, vol. 92, p. 277. https://doi.org/10.1007/s00170-017-0039-1
  16. Velmurugan, C., Senthilkumar, V., Dinesh, S., and Arulkirubakaran, D., Machining of NiTi-shape memory alloys – a review, Mach. Sci. Technol., 2017, vol. 22, no. 3, p. 355.
  17. Adam Ruszaj, Some aspects of electrochemical machining process modeling and applications, Adv. Manuf. Sci. Technol., 2017, vol. 41, no. 4. https://doi.org/10.2478/amst-2017-0018
  18. Davydov, A.D., Volgin, V.M., and Lyubimov, V.V., Electrochemical machining of metals: fundamentals of electrochemical shaping, Russ. J. Electrochem., 2004, vol. 40, no. 12, p. 1230.
  19. Zhu, D., Wang, K., and Qu, N.S., Micro wire electrochemical cutting by using in situ fabricated wire electrode, CIRP Ann., 2007, vol. 56, no. 1, p. 241.