Influence of electrochemical machining parameters on metal removal rate MRR and surface roughness

Dissertant

Ahmad, Baqir Iyad

Thesis advisor

Shadhar, Sad Karim
Abd, Salah A.

University

University of Technology

Faculty

-

Department

Department of Production Engineering and Metallurgy

University Country

Iraq

Degree

Master

Degree Date

2011

English Abstract

-In this study the ECM is used to remove metal from the internal hole of the workpiece (Al Zn Mg Cu1.5-DIN 1725-1) using NaCl solution.

To study the influence of (electrolyte concentration, current density, tool rotation, and electrolyte flow rate) on Metal Removal Rate (MRR) and surface roughness (Ra).

Also study the influence of voltage and frequency of pulsed power supply on MRR , and machine a complex shape by ECM and small holes array.

The results showed that:- the increasing of electrolyte concentration from (100 to 500) g/l causes enhancement of MRR by (8.99%) , and Ra increases at concentration of (500 g/l) by (34.34%) compared with (100 g/l).

So increasing of current density from (2.82 to 8.4883 )A/cm2 the MRR will increase by (66.66%), and increasing current density produces a smoother surface roughness (better finish), the surface roughness decreases reaching the value of (1.115μm) with a current density of (8.48A/cm2).

Improvement in MRR and dissolution rate by using the rotational tool is compared with the stationary tool.

The rates of improvement in MRR are (6.48, 1.81, 3.74, 13.24, 3.11) % for current densities of (2.82, 4.24, 5.65, 7.07, 8.48) A/cm2 respectively, when compared with the stationary tool.

The rotating electrode gives better surface finish than the stationary electrode, were the enhancement rates are (7, 31.72, 7.91, 15.49, 1.34)% for current density values of (2.82, 4.24, 5.65, 7.07, 8.48) A/cm2 respectively.

The MRR increases at flow rate of (14 l/min) by (17.74%) as compared with (6 l/min), and The Ra enhancement with increasing the electrolyte flow rate, the enhancement rate of Ra at electrolyte flow rate (14) l/min reached to (63.07%) when compared with flow rate (6) l/min.

The increasing of voltage from (10 to 30) V causes increasing in MRR by (29.45%).

Also the increasing in the frequency of pulsed power supply causes improvement in MRR ,were the MRR improved by (34.17%) when the frequency increases from (100 to 500) Hz.

Genatic Neural Network (GNN) software is used to predict the results.

Main Subjects

Civil Engineering

Topics

• Minerals
• Machining
• Cutting
• Friction

• APA
• MLA
• AMA

Language

English

Data Type

Arab Theses

Record ID

BIM-305214