| Modelling Overcut Dynamics in Electrochemical
Discharge Drilling of Alumina (Al2O3
) Ceramics |
Shyam Sunder Suthara,* and Vikas Kumarb
Pages : 245-253
DOI: 10.1080/0371750X.2025.2546368 |
| Abstract |
| Demand of alumina (Al2O3
) ceramics is increasing exponentially in various industries,
where dimensional accuracy is paramount. Overcut is a major issue during the
machining through electro-chemical discharge machining (ECDM) that affects the
dimensional accuracy. Material removal mechanism plays a vital role in ECDM which
is affected by electrolyte concentration and applied voltage. Overcut, related to ECDM
process, is possibly reduced by understanding the effect of these parameters. A
mathematical model is explained to predict the overcut associated with ECDM in
which material removal is based on thermal effect. The key input parameters of model
are mean machining current and electrolyte resistance which are function of electrolyte
concentration. The model not only describes the effect of electrolyte concentration
but also describes the effect of machining time on overcut. Further, Scilab software
is used for simulating the model. The simulation resulted in 2D plots for temperature
difference and overcut with varying electrolyte concentrations for voltage range of
40-55 V. Results demonstrate that increasing electrolyte concentration and applied
voltage significantly increase the overcut. The presented model exhibits 14% error.
Comparative analysis confirms the robustness of the model and its reliability in
predicting the overcut trends under varying machining conditions.
[Keywords: Electrochemical, Alumina, Ceramics, Model, Overcut] |
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