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<p>In past, several studies have been reported on the using inter-electrode slits for enhancing the efficiency of electrochemical machining (ECM) in terms of material removal rate (MRR), surface roughness (R<sub>a</sub>), dimensional stability, surface characteristics, etc. However, limited studies have been reported on developing the ECM process’s digital thread (DT) to enhance its efficiency as a tool room process. This study focuses on the design and development of a DT by using a microstrip patch antenna (MPA) based passive sensor, which has been used as an inter-electrode slit (IES) for replicating the shape of the Cu alloy tool over the stainless steel (SS) workpiece (W/P). The 3D-printed IES by fused filament fabrication (FFF) of acrylonitrile butadiene styrene (ABS) as a dielectric substrate was used to measure the change in dielectric properties (dielectric constant (ε<sub>r</sub>) and loss tangent (tanδ)) online, at different machining conditions without and with stimuli (10&#xa0;ml electrolyte (saline water); 5–15&#xa0;mg of sludge formed) through vector network analyzer. The continuous change in dielectric properties leading to a shift in resonance frequency (f<sub>r</sub>) (from 2.47 to 1.78&#xa0;GHz) and insertion loss (S<sub>21</sub>) of the IES from −31.68 to −26.64&#xa0;dB resulted in the development of DT for online monitoring of ECM.</p>

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Digital Thread for Online Monitoring of Electrochemical Machining

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • Abhishek Barwar,
  • Rupinder Singh

摘要

In past, several studies have been reported on the using inter-electrode slits for enhancing the efficiency of electrochemical machining (ECM) in terms of material removal rate (MRR), surface roughness (Ra), dimensional stability, surface characteristics, etc. However, limited studies have been reported on developing the ECM process’s digital thread (DT) to enhance its efficiency as a tool room process. This study focuses on the design and development of a DT by using a microstrip patch antenna (MPA) based passive sensor, which has been used as an inter-electrode slit (IES) for replicating the shape of the Cu alloy tool over the stainless steel (SS) workpiece (W/P). The 3D-printed IES by fused filament fabrication (FFF) of acrylonitrile butadiene styrene (ABS) as a dielectric substrate was used to measure the change in dielectric properties (dielectric constant (εr) and loss tangent (tanδ)) online, at different machining conditions without and with stimuli (10 ml electrolyte (saline water); 5–15 mg of sludge formed) through vector network analyzer. The continuous change in dielectric properties leading to a shift in resonance frequency (fr) (from 2.47 to 1.78 GHz) and insertion loss (S21) of the IES from −31.68 to −26.64 dB resulted in the development of DT for online monitoring of ECM.