Experimental investigation on ecmm of hardened die steel using nano particles mixed electrolytes

Abstract

The Electro Chemical Micro Machining (ECMM) is an advanced technique of Electro Chemical Machining (ECM) process, which is classified as one of the modern machining processes. The two major advantages of ECM are machining of hard, with electrically conductive materials and the non-contact of tool with workpiece machining, which produces higher quality of surface finish along with elimination of tool wear. In ECMM the micro-machining occurs due to metal dissolution as a result of the anodic reaction, and it is just a reversal of electroplating process. This ECMM process is employed by manufacturing industries to produce precise components from hard metals for aeronautical industries to common die-sinking operations. The objective of this research work is the parametric optimization of ECMM by machining Hardened Die Steel (HDS). The die steel contains high carbon content, which provides improved strength and hardness to ordinary steel. The hardness and wear resistance of the die steel is further increased using the hardening process. The HDS has many applications in manufacturing industries, one of the major applications is punching tools production. The HDS also has a low thermal expansion, which allows to produce the products with high precision and better dimensional accuracy. Apart from the various advantages, the major setback encountered is the hardness and brittleness of HDS and it makes machining and production operations as challenge and a complex process. In this research work, an attempt has been made for the improvement in the performance efficiency of the ECMM process, by utilizing a different combination of electrolytes with suspended nanoparticles. The addition of nanoparticles in the electrolyte improve its electrical and thermal properties, which in turn enhances the machining efficiency. newline