TOWARDS HIGHER ACCURACY FOR ECM HYBRIDIZED WITH LOW FREQUENCY VIBRATIONS USING THE RESPONSE SURFACE METHODOLOGY | ||||
ERJ. Engineering Research Journal | ||||
Article 4, Volume 26, Issue 4, October 2003, Page 63-74 PDF (3.19 MB) | ||||
Document Type: Original Article | ||||
DOI: 10.21608/erjm.2003.82589 | ||||
![]() | ||||
Authors | ||||
S. J. Ebeid1; M. S. Hewidy2; T. A. El-Taweel2; A. H. Youssef2 | ||||
1Ain Shams University, Faculty of Engineering, Cairo, Egypt. | ||||
2Menoufia University, Faculty of Engineering, Shebin El-Kom, Egypt. | ||||
Abstract | ||||
Electrochemical machining (ECM) provides a beneficial alternative for machining complex shapes in advanced materials. However, the relatively low machining accuracy with difficulties in tool design and electrolyte disposal has limited ECM to become a commonly used technology. The present work addresses the improvement of machining accuracy in ECM by hybridizing the process by low frequency vibrations. The study highlights the development of mathematical models for correlating the inter relationships of various machining parameters such as applied voltage, feed rate, back pressure and vibration amplitude on overcut and conicity for achieving high controlled accuracy. This work has been based on the response surface methodology (RSM), This investigation also highlights the various test results that confirm the validity and correctivness of the developed mathematical models for analyzing the effect of the various process parameters on the overcut and conicity. Experimental results reveal useful relationships between the low-frequency vibration parameters and the ECM inter electrode gap and hence the overcut phenomenon. Although the hybridization element seems to be simple, it has led to a significant improvement in the electrochemical machining accuracy. The results also indicate that the assistance of low-frequency vibrations to the ECM process seems to be promising and competitive specially when sculptured surfaces are required to be produced as found particularly in cavities of dies and also in an industrial era of miniaturization. | ||||
Keywords | ||||
Electrochemical machining (ECM); Dimensional accuracy; Response surface methodology (RSM) | ||||
Statistics Article View: 107 PDF Download: 183 |
||||