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Regulation of Spark and Effect of Stray Current in ECM Process

Rohit Kumar Sharma, Anil Kumar Sharma


Electrochemical machining has proved its immense potential to be used as an alternative technique to machine-complicated profile on electrically conducting materials. The performance of electrochemical machining can be increased with diminishing mini-sparking and stray-current MR by proper regulation of machining parameters. Through this paper, an endeavor has been created to ascertain comprehensive mathematical model for correlating the interactive and higher order influences of assorted machining parameters on the mix result of micro-spark and stray-current machining, through response surface methodology approach. Validity and correctiveness of the developed mathematical model for analyzing the effects of various parameters on the micro-spark and stray-current-affected zone (MSAZ) is highlighted through different plots. Machined holes are also analyzed through SEM graphs. MSAZ is reduced to as low as 0.0001 mm under proper controlled parametric combination of pulse on/off ratio of 2.1618, machining voltage of 2.8347 V, electrolyte concentration of 10 g/l, voltage frequency of 35% per second, and gear vibration frequency as 100 cycles per second.

Keywords: EMM, micro-spark and stray-current-affected zone (MSAZ), RSM

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