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An Experimental Investigation of Surface Characterization for Zirconia Ceramic Using Electrochemical Discharge Machining Process

  • Research Article-Mechanical Engineering
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Abstract

The industrial acceptance of ceramic materials is gradually increasing because of their attractive properties such as high strength, hot hardness, biocompatibility, insulating, and chemical stability over monolithic materials. The Zirconia (ZrO2) is a ceramic material of nonconductive and brittle in nature; thereby, it is very difficult to machine by very popular well-known machining methods like ECM, WEDM, EDM, etc. The machining problem resists its industrial applications. To overcome this problem, electrochemical discharge machining (ECDM) is a combination of electrochemical and electrical discharge machining methods used to machine the nonconductive ZrO2 material. The effects of machining parameters on machining responses were analysed through different graphs. Taguchi method-based L16 (45) orthogonal array was employed and utilized the acquired results to optimize the machining parameters. The experimental results reveal that the DC supply voltage and electrolyte concentration are the main governing factors in controlling the machining performance. The better material removal rate was identified at 65 V, 16 g/l electrolyte concentration, and 60-mm inter-electrode gap. FESEM images identified some of the micro-cracks on the machined hole surface when machining operations were carried out at a higher level of parameter setting. The presence of iron (Fe) was identified from EDS analysis, and it may be due to the diffused part of the steel cathode adhering to the machined surface.

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Abbreviations

AC:

Alternative current

Adj MS:

Adjusted mean square

Adj SS:

Adjusted sum of square

ANOVA:

Analysis of variance

DC:

Direct current

DF :

Duty factor

DOF:

Degrees of freedom

EC:

Electrolyte concentration

ECDM:

Electrochemical discharge machining

ECM:

Electrochemical machining

EDM:

Electric discharge machining

FESEM:

Field emission scanning electron microscope

IEG:

Inter-electrode gap

MEMS:

Micro-electromechanical system

MOEMS:

Micro-optoelectromechanical system

MRR:

Material removal rate

MSD:

Mean square deviation

NaOH:

Sodium hydroxide

OA:

Orthogonal array

S/N ratio:

Signal-to-noise ratio

SR:

Surface roughness

SS:

Stainless steel

TWR:

Tool wear rate

V:

DC supply voltage

WC:

Tungsten carbide

(W)OC:

(Width of) overcut

%:

Percentage

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Authors and Affiliations

  1. Department of Production and Industrial Engineering, Punjab Engineering College (Deemed to be University), Chandigarh, 160012, India

    Manoj Kumar, R. O. Vaishya & N. M. Suri

  2. Department of Mechanical Engineering, Punjab Engineering College (Deemed to be University), Chandigarh, 160012, India

    Alakesh Manna

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  1. Manoj Kumar
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  2. R. O. Vaishya
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Correspondence to Manoj Kumar.

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Kumar, M., Vaishya, R.O., Suri, N.M. et al. An Experimental Investigation of Surface Characterization for Zirconia Ceramic Using Electrochemical Discharge Machining Process. Arab J Sci Eng 46, 2269–2281 (2021). https://doi.org/10.1007/s13369-020-05059-4

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