Modelling and analysis on performance of ECDM process for the fabrication of μ-channels on glass through response surface methodology

Abstract

The process electro-chemical discharge micro-machining can be utilized to produce micro-channels, micro-profiles, blind holes and miniature parts with ceramic, composite, quartz and glass. This research paper enlightens the development of micro-ECDM system and the influences of process variables like duty ratio (%), pulse frequency (Hz), electrolyte concentration (wt%) and applied voltage (V) on material removal rate (MRR), overcut (OC), heat affected zone (HAZ) and surface roughness (Ra) to improve the machining efficiency as well as better quality of surface integrity during micro-channel cutting on glass using spring feed mechanism in ECDM process. The mathematical models of above machining criteria are established with help of response surface methodology (RSM) and their adequacies have been justified through Analysis of Variance (ANOVA) test. This research article also emphasises on the single and multi-objective optimization to find out suitable parametric condition for micro-channel cutting on glass. MRR is found maximum at 55V/30wt%NaOH/40%/200Hz and better surface quality of μ-channel is achieved with higher machining depth at 35V/30wt%NaOH/60%/660Hz. Further, this research paper includes a qualitative analysis of micro-channels based on SEM and XRD analyses to identify the phase change, micro-cracks and presence of uncut silica debris in the channels.