Abstract
Electrochemical discharge machining (ECDM) is a novel non-conventional processing method that entails high-temperature melting and enhanced chemical etching facilitated by substantial electrical energy discharge. The present research article presents experimental findings on the effects of tool rotation and tool–workpiece (T–W) gap on the geometric characteristics of drill holes formed in a zirconia workpiece during the ECDM process. In addition, the influence of a one-micron-thick platinum-plated tool is also used to analyze the surface texture of the micro-hole formed in the ceramic. The effect of various process parameters is explored, including applied voltage range (90–110 V), electrolyte concentration (25%–35%), lower pulse frequencies (10–30 kHz), tool rotation speeds (10–50 rpm), and T–W gap (0–30 µm). The discharge-affected zone on the workpiece, due to sparking, and the surface topography of the machined zone have been studied using a scanning electron microscope. The difference in shape of the heat flux projected on the machining zone and the temperature distribution on the workpiece, with and without tool rotation, has been generated by the thermo-gun. The topographical study of the machined surface and the temperature distribution reveals the potential use of this indigenously designed and developed ECDM setup for machining on ceramics in the micron regime. Furthermore, the statistical analysis using the Taguchi L27 design, S/N ratio, analysis of variance, and regression modeling revealed that applied voltage is the most dominant parameter, contributing nearly 48% to material removal rate and 28% to radial overcut, with significant effects at a 95% confidence level.
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