Estimation of MRR Using U-Shape Electrode in Electrochemical Machining

Abstract

Non-traditional machining has grown out of the need to machine exotic engineering metallic materials, composite materials and high tech ceramics having good mechanical properties and thermal characteristics as well as sufficient electrical conductivity. Electrochemical Machining developed in late 1950’s has been accepted worldwide as a standard process in manufacturing and is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries. The principle of anodic dissolution of metal theory is the most accepted mathematical model for evaluating material removal from electrodes during electrochemical process. If two suitable metal poles are placed in a conducting electrolyte and a direct current passed through them, the metal on the positive pole get depleted and its material is deposited on the negative pole. Keeping this in view, the present work has been undertaken to finding the material removal rate by electrochemical dissolution of an anodically polarized work piece with a U-shaped tubular copper electrode. In the experiment, AISI D2 steel is used as specimen. Experiments were carried out to study the influence of machining parameters such as feed rate, applied voltage, conductivity and flow rate on the over cuts in length, width and height of the specified cavity.