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82589

TOWARDS HIGHER ACCURACY FOR ECM HYBRIDIZED WITH LOW FREQUENCY VIBRATIONS USING THE RESPONSE SURFACE METHODOLOGY

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Last updated: 04 Jan 2025

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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.

DOI

10.21608/erjm.2003.82589

Keywords

Electrochemical machining (ECM), dimensional accuracy, Response Surface Methodology (RSM)

Authors

First Name

S.

Last Name

J. Ebeid

MiddleName

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Affiliation

Ain Shams University, Faculty of Engineering, Cairo, Egypt.

Email

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City

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Orcid

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First Name

M.

Last Name

S. Hewidy

MiddleName

-

Affiliation

Menoufia University, Faculty of Engineering, Shebin El-Kom, Egypt.

Email

-

City

-

Orcid

-

First Name

T.

Last Name

A. El-Taweel

MiddleName

-

Affiliation

Menoufia University, Faculty of Engineering, Shebin El-Kom, Egypt.

Email

-

City

-

Orcid

-

First Name

A.

Last Name

H. Youssef

MiddleName

-

Affiliation

Menoufia University, Faculty of Engineering, Shebin El-Kom, Egypt.

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Orcid

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Volume

26

Article Issue

4

Related Issue

12459

Issue Date

2003-10-01

Receive Date

2020-04-15

Publish Date

2003-10-01

Page Start

63

Page End

74

Print ISSN

1110-1180

Online ISSN

3009-6944

Article File

ERJM_Volume 26_Issue 4_Pages 63-74.pdf

PDF . 3.3MB

Link

https://erjm.journals.ekb.eg/article_82589.html

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https://erjm.journals.ekb.eg/service?article_code=82589

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Original Article

Type Code

1,118

Publication Type

Journal

Publication Title

ERJ. Engineering Research Journal

Publication Link

https://erjm.journals.ekb.eg/

MainTitle

TOWARDS HIGHER ACCURACY FOR ECM HYBRIDIZED WITH LOW FREQUENCY VIBRATIONS USING THE RESPONSE SURFACE METHODOLOGY

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Article

Created At

22 Jan 2023