https://orcid.org/0000-0001-6706-1877
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ABSTRACT
The tool electrode feed rate (TEFR) is a parameter of vital importance for velocity-feed electrochemical discharge drilling (ECDD). The tool electrode will hit the workpiece and may even cause to crack if higher TEFR is used, while a lower TEFR will curtail the material etch rate. Hence, a comprehensive experimental study into the TEFR effects on the ECDD performance is presented. The top and bottom sizes of micro-holes, eccentricity, circularity, heat-affected zone, and tool electrode wear are the important features considered in this experimental work. Cylindrical-shaped tungsten carbide tool electrodes with 70 μm and 300 μm sizes were utilized. The TEFR in the range of 1–9 μm s−1 were selected. The stable and uniform EC discharges were observed for the TEFR < 5 μm s−1. The minimal hole size and HAZ were obtained for the TEFR in the range of 3–4 μm s−1. The eccentricity and circularity of micro-holes were found to be lower for the TEFR < 5 μm s−1. Higher tool wear was noticed for the TEFR < 2 μm s−1. Based on the overall experimental evaluation, TEFR in the range of 3–4 μm s−1 is recommended.
Acknowledgments
The authors appreciate the financial funding provided by the Ministry of Human Resources and Development (MHRD) as well as the Department of Scientific and Industrial Research (DSIR) (Grant: DSIR/PACE/TDD-IMPRINT/7510). Present work has been conducted as a part of MHRD, Govt. of India funded IMPRINT Project (Grant code: 10007457). J Arab is supported by the Inspire fellowship (Grant number: DST/INSPIRE fellowship/2017/IF160295) of the Department of Science and Technology (DST).