Modelling and simulation of MRR in electro-chemical surface grinding of Al-SiC-Gr using hybrid analytical approach

Abstract

Electro-Chemical Surface Grinding (ECSG) is a hybrid machining process which utilizes synergic actions of three sub-processes viz. electrochemical dissolution, grinding action of abrasive particles and erosive action of electrolyte flow in inter electrode gap. Since, occurrence of turbulence in machining zone significantly affects the machining performance, it is required to analyze the turbulence phenomenon in ECSG process. The exact solution and Numerical solution–based hybrid analytical approach has been used to predict the Material Removal Rate (MRR) in ECSG of Al-SiC-Gr. In this model, the streaming potential of electrolytic action, abrasive action of grinding wheel and shear force of electrolyte flow between inter electrode gap have been considered. Finite Element Method based Numerical modelling has been carried out to analyze the electrolyte flow in machining zone in order to evaluate the MRR due to erosive action. It was observed that the application of shear force on oxide layer rises with the increase in flow rate of electrolyte. Confirmation experiment has been performed to validate the modelling results. Validation results show a minor error of 8.21% in prediction of MRR using analytical as well as finite element model.

Keywords

Abrasion shear force computational fluid dynamics electro-chemical machining electro-chemical surface grinding material removal rate

Get full access to this article

View all access options for this article.

References

Benedict

. Nontraditional manufacturing process. New York: CRC Press, 1987.

Jain

. Advanced machining process. New Delhi: Allied publishers, 2002.

Ghosh

Mallik

. Manufacturing science. Barakhamba road. New Delhi: EWP private limited, 2009.

Saxena

Bellotti

Camp

, et al. Electrochemical based hybrid machining. In: Luo

Qin

(eds) Hybrid machining. Cambridge: Academic Press. 2018, pp. 111–129.

Patel

Jain

Ramkumar

. Electrochemical grinding. In: Jain

(ed) Nanofinishing science and technology. New York: CRC Press, 2019, pp. 111–129.

Pandey

Shan

. Modern machining process. New Delhi: Tata McGraw-Hill Publishing Company Ltd, 1997.

Puri

Banerjee

. Multiple-response optimization of electrochemical grinding characteristics through response surface methodology. Int J Adv Manuf Technol 2013; 64: 715–725.

Tehrani

Atkinson

. Overcut in pulse electrochemical grinding. Proc IMechE Part B: J Eng Manuf 2000; 214: 259–269.

Nomura

, et al. Fundamental machining characteristics of ultrasonic assisted electrochemical grinding of Ti-6Al-4V. J Manuf Sci Eng 2018; 140: 071009.

10.

Goswami

Mitra

Sarkar

. Experimental investigation on electrochemical grinding (ECG) of alumina-aluminum interpenetrating phase composite. Int J Adv Manuf Technol 2009; 40: 729–741.

11.

Gaikwad

Joshi

. Modeling of material removal rate in micro-ECG process. J Manuf Sci Eng 2008; 130: 0345021–0345027.

12.

Ilhan

Sathyanarayanan

Storer

, et al. A study of wheel wears in electrochemical surface grinding. J Eng Ind 1992; 114: 82–93.

13.

Sapre

Mall

Joshi

. Analysis of electrolytic flow effects in micro-electrochemical grinding. J Eng Ind 2013; 135: 1–9.

14.

Rahi

Dubey

. A study on the effect of voltage on performance characteristics of electrochemical surface grinding of HMMC. Mater Today Proc 2021; 44: 1444–1447.

15.

Gupta

Dubey

Rahi

. Analysis of electrolyte flow in IEG during electrochemical grinding of MMC. In: Kalamkar

Monkova

(eds) Proceedings of ICAME 2020. Singapore: Springer, 2020, pp. 307–316. 10.1007/978-981-15-3639-7.

16.

Kaushal

Narayan

. Experimental setup development and parametric study of electrochemical face grinding process using Ni-based superalloy. Int J Abras Technol 2020; 10: 1–15.

17.

Yadav

SKS

. Multi-Objective optimization of electrochemical cut-off grinding process of Ti-6Al-4 V using PCA based grey relational analysis. Mater Today Proc 2019; 22: 3089–3099.

18.

Matharou

Bhuyan

. Modelling and combined effect analysis of electric discharge machining process using response surface methodology. Mater Today Proc 2020; 46: 6638–6643.

19.

Rahi

Dubey

. Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG. Proc IMechE Part C: J Mech Eng Sci 2022; 336: 6740–6751.

20.

Bhuyan

Garg

Gupta

. Design and development of tabletop electrochemical grinding setup. Mater Today Proc 2020; 21: 1479–1482.

21.

Ma X, Jiao F, Niu Y, et al. Modeling of the material removal rate in internal cylindrical plunge electrochemical grinding. J Manuf Process 2023; 92: 89–106.

22.

Levinger

Malkin

. Electrochemical grinding of WC-co cemented carbides. J Manuf Sci Eng 1979; 101: 285–229.

23.

Cole

. An experimental investigation of the electrolytic grinding process. J Manuf Sci Eng 1961; 83(2): 194–201.

24.

Kumar

. Fluid mechanics and hydraulic machine. Pearson India, 2019.

25.

Mala

Werner

, et al. Flow characteristics of water through a microchannel between two parallel plates with electrokinetic effects. Int J Heat Fluid Flow 1997; 97: 489–496.

26.

Yang

. Analysis of electrokinetic effects on the liquid flow in rectangular microchannels. Colloids Surf, A 1998; 143: 339–353.

27.

Chang

Hashimura

Dornfeld

. An investigation of material removal mechanisms in lapping. J Manuf Sci Eng 2016; 122: 413–419.

28.

Blazek

. Computational fluid dynamics: Principles and applications. 2nd ed. London: Elsevier Ltd, 2003.

Supplementary Material

Please find the following supplemental material available below.

For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.

For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.

0.00 MB

0.02 MB

0.05 MB