Experimental Investigation of MRR on Inconel 600 using Ultrasonic Assisted Pulse Electrochemical Machining

The non-traditional machining processes are commonly used for the materials which are hard and difficult to cut by conventional machining processes. One of the most commonly used non-conventional machining processes is electro chemical machining process. Electrochemical machining (ECM) is a modern machining process that relies on the removal of workpiece atoms by electrochemical dissolution (ECD) in accordance with the principles of Faraday.In electro chemical machining process, the tool and work piece don't have any physical contact, resulting in negligible tool wear. Electrolyte in the process, which carries the current from the work piece to tool, removes the work piece material and generates the sludge. The electrolyte carriers the sludge out of machining zone.Experiments are performed on developed setup to obtain optimized parameters of USAPECM for the maximum MRR and minimum overcut. The influence of 5 parameters specifically Voltage, Pulse on time, ultrasonic on time, ultrasonic off time and amplitude of vibration on MRR and overcut are studied. The experiments are conducted based on Taguchi technique with L₂₇ orthogonal array. (paper)