Micro-Channel Cutting on Glass in Electrochemical Discharge Machining Process Using Different Electrolytes and Tool Polarity

Microchannel cutting on electrically nonconducting materials with electrochemical discharge machining (ECDM) process has drawn a momentous attention in manufacturing field as compared to other existing nontraditional machining processes. In the present research work, an effort has been accomplished to investigate the effects of process parameters, namely, applied voltage (V), electrolyte concentrations(wt%), pulse frequency, and duty ratio on different performance characteristics of ECDM viz., material removal rate (MRR), overcut (OC) and heat-affected zone (HAZ) area during microchannel cutting on glass. Also, the comparative performance studies during microchannel cutting have been done by using mixed electrolyte of NaOH and KOH and different tool polarities. Overcut is measured as lower (42.26 μm) when aqueous KOH electrolyte is used and as higher (133.44 μm) for aqueous NaOH electrolyte. HAZ enlarges with enrichment in concentration for both types of electrolyte. It is observed that polarity has a vital role on various machining characteristics. As compared to direct polarity, MRR is found very low (3.2 mg/h) in reverse polarity of tool. Overcut is found low in KOH electrolyte for both types of tool polarity (i.e., 64.68 μm for direct polarity and 42.27 μm for reverse polarity). The process parameters influence on the surface texture of microchannels. Microcrack is noticed for direct polarity of tool.