Experimental investigation of machined hole and optimization of machining parameters using electrochemical machining

The electrochemical micromachining in non-conventional machining which suffers from process control in micro level. In addition, the work material i.e. stainless steel provides high strength, high toughness and adherence to tool material, hence machining of such material is arduous. However, the use of stainless steel offers its availability in the field of aerospace fuel injection and orthodontic application, since it possess superior qualities. In this paper, the optimization of micro drilling process is carried out in stainless steel by considering certain metrics like feed rate, voltage and duty ratio. The geometric characteristics to drill the tool depends on response parameters like overcut, removal rate of material and conicity. Such parameter determines both the geometric and machining characteristics of the drill bit. The study is evaluated to observe the effect of response and duty ratio parameters such as material removal rate (MRR), machining time and overcut. Further, the conicity is analyzed using VMS images. Finally, the proposed work establishes duty cycle in pulsed electrochemical micromachining domain of hard materials and tests its performance. (C) 2019 The Author. Published by Elsevier B.V.