Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy
The usage of scrapped wheel alloys offered significant potential in promoting resource conservation, innovative applications, and environmental sustainability. This study investigated the optimization of micro-hole formation in scrapped wheel alloy using Electrochemical Machining (ECM), with the nov...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-01-01
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| Series: | Results in Surfaces and Interfaces |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666845925000169 |
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| author | D. Sriram B.D.Y. Sunil S. Jeyakrishnan C. Rakesh S. Vijayakumar Ashish Kumar N. Rao Cheepurupalli Lakshita Sehgal |
| author_facet | D. Sriram B.D.Y. Sunil S. Jeyakrishnan C. Rakesh S. Vijayakumar Ashish Kumar N. Rao Cheepurupalli Lakshita Sehgal |
| author_sort | D. Sriram |
| collection | DOAJ |
| description | The usage of scrapped wheel alloys offered significant potential in promoting resource conservation, innovative applications, and environmental sustainability. This study investigated the optimization of micro-hole formation in scrapped wheel alloy using Electrochemical Machining (ECM), with the novelty of employing Potassium Chloride (KCl) as an electrolyte. Potassium Chloride (KCl), Sodium Nitrate (NaNO₃) and Sodium Chloride (NaCl) used to evaluate the impact of electrolyte type on machining performance. Voltage (VO), Duty Cycle (DU), and Electrolyte Concentration (EL) were optimized to enhance Material Removal Rate (MRR) and minimize Overcut (OC) using the Taguchi-Grey Relation Analysis method. The optimal process parameters were recognized as VO of 14 V, DU of 85%, and EL of 50 g/L, attaining an MRR of 2.752 g/min and an OC of 0.068 mm. Additionally, SEM analysis revealed superior machining characteristics under optimal conditions, including minimal micro-cracks, reduced delamination, and enhanced circularity. The study highlights the uniform distribution of current density across the workpiece, resulting in reliable material removal and improved machining results. These findings demonstrate the feasibility of using KCl as an electrolyte in ECM for sustainable and efficient machining of scrapped wheel alloys, offering advancements in precision manufacturing and resource optimization. |
| format | Article |
| id | doaj-art-9e84160de56c4ed48238729522d2ee14 |
| institution | Kabale University |
| issn | 2666-8459 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Surfaces and Interfaces |
| spelling | doaj-art-9e84160de56c4ed48238729522d2ee142025-01-31T05:12:34ZengElsevierResults in Surfaces and Interfaces2666-84592025-01-0118100429Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloyD. Sriram0B.D.Y. Sunil1S. Jeyakrishnan2C. Rakesh3S. Vijayakumar4Ashish Kumar5N. Rao Cheepurupalli6Lakshita Sehgal7Department of Mechanical Engineering, Indra Ganesan College of Engineering, Manikandam, Trichy, 620012, IndiaDepartment of Mechanical Engineering, Institute of Aeronautical Engineering, Hyderabad, IndiaDepartment of Mechanical Engineering, ARM College of Engineering and Technology, Maraimalainagar, Chennai, 603209, IndiaDepartment of Mechanical Engineering, New Horizon College of Engineering, Bangalore, IndiaDepartment of Mechanical Engineering, Graphic Era Hill University, Dehradun, 248002, Uttarakhand, India; Department of Mechanical Engineering, Graphic Era Deemed to be University, Dehradun, 248002, Uttarakhand, IndiaDivision of Research and Development, Lovely Professional University, Phagwara, India; Corresponding author.Department of Mineral Processing and Metallurgical Engineering, Faculty of Mines, Aksum University, EthiopiaCentre for Research Impact & Outcome, Chitkara University Institute of Engineering and Technology, Chitkara University, Rajpura, 140401, Punjab, IndiaThe usage of scrapped wheel alloys offered significant potential in promoting resource conservation, innovative applications, and environmental sustainability. This study investigated the optimization of micro-hole formation in scrapped wheel alloy using Electrochemical Machining (ECM), with the novelty of employing Potassium Chloride (KCl) as an electrolyte. Potassium Chloride (KCl), Sodium Nitrate (NaNO₃) and Sodium Chloride (NaCl) used to evaluate the impact of electrolyte type on machining performance. Voltage (VO), Duty Cycle (DU), and Electrolyte Concentration (EL) were optimized to enhance Material Removal Rate (MRR) and minimize Overcut (OC) using the Taguchi-Grey Relation Analysis method. The optimal process parameters were recognized as VO of 14 V, DU of 85%, and EL of 50 g/L, attaining an MRR of 2.752 g/min and an OC of 0.068 mm. Additionally, SEM analysis revealed superior machining characteristics under optimal conditions, including minimal micro-cracks, reduced delamination, and enhanced circularity. The study highlights the uniform distribution of current density across the workpiece, resulting in reliable material removal and improved machining results. These findings demonstrate the feasibility of using KCl as an electrolyte in ECM for sustainable and efficient machining of scrapped wheel alloys, offering advancements in precision manufacturing and resource optimization.http://www.sciencedirect.com/science/article/pii/S2666845925000169ECMScrapped alloyOptimizationMRROC and GRA technique |
| spellingShingle | D. Sriram B.D.Y. Sunil S. Jeyakrishnan C. Rakesh S. Vijayakumar Ashish Kumar N. Rao Cheepurupalli Lakshita Sehgal Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy Results in Surfaces and Interfaces ECM Scrapped alloy Optimization MRR OC and GRA technique |
| title | Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy |
| title_full | Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy |
| title_fullStr | Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy |
| title_full_unstemmed | Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy |
| title_short | Investigation of different electrolyte effects on micro-hole machining of scrapped wheel alloy |
| title_sort | investigation of different electrolyte effects on micro hole machining of scrapped wheel alloy |
| topic | ECM Scrapped alloy Optimization MRR OC and GRA technique |
| url | http://www.sciencedirect.com/science/article/pii/S2666845925000169 |
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