https://orcid.org/0000-0002-7046-9766
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ABSTRACT
Electrochemical milling (EC milling) has great possibility in consequence of its flexibility and applications in the various manufacturing industries, especially in defense and biomedical industry. In future, it is likely to be one of the most capable, successful, and commercially used unconventional machining processes in the up-to-date manufacturing industries. In this research work, an attempt has been made to develop a versatile in-house EC milling setup to study the impact of inner-spraying rotating tool on the different responses of EC milling. Experiments have been performed on a special type of nickel-based (nickel–cobalt–chromium–molybdenum) superalloy commonly known as Nimonic-263 alloy specially developed for high-temperature and high-strength applications to identify the impact of major process parameters, e.g., feed rate and milling layer depth with and without tool rotation, on the responses like machining depth, side angle, surface roughness, and quality of machined profile. During EC milling of Nimonic-263 alloy, excellent surface finish ranging from 0.06 to 0.08 μm has been attained by employing mixed electrolyte, i.e., NaCl (1 M) and NaNO3(1 M). With the incorporation of inner-spraying rotating tool, flushing can be improved to a large extent which improves the accuracy of machining.