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<p>Electrochemical discharge machining (ECDM) represents an advanced technique for processing insulative and difficult-to-machine materials. This study investigates the performance of a mixed electrolyte composed of Potassium hydroxide (KOH) and Sodium hydroxide (NaOH) at a fixed concentration of 15 wt%. Experimental investigations reveal that the mixed electrolyte (NaOH + KOH) significantly improves Material removal rate (MRR), and minimizes Overcut (OC), and Tool wear rate (TWR) compared to individual NaOH and KOH electrolytes. The study employs the Taguchi method and Grey relational analysis (GRA) to identify the ideal parameter settings that enhance machining performance. The Analysis of variance (ANOVA) results for the Grey relational grade (GRG) study indicated that voltage has the most significant effect on output responses, contributing 75.58% to the variation, followed by duty cycle at 6.02%, frequency at 2.34%, feed rate at 4.59%, and tool wp gap at 5.25%. Additionally, the regression equations were developed to determine the ideal parametric combination. This study highlights the potential of mixed electrolytes in optimizing the ECDM process for better efficiency and superior surface quality, paving the way for advancements in precision machining applications.</p>

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Optimization of ECDM Process Parameters for Microchannel Fabrication Through Mixed Electrolyte in Borosilicate Glass Using Taguchi-GRA Approach

  • 期刊论文

  • 发表日期：

    2025年5月1日

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  • Akshay Doke,
  • Avinash M. Badadhe,
  • N. S. Mujumdar

摘要

Electrochemical discharge machining (ECDM) represents an advanced technique for processing insulative and difficult-to-machine materials. This study investigates the performance of a mixed electrolyte composed of Potassium hydroxide (KOH) and Sodium hydroxide (NaOH) at a fixed concentration of 15 wt%. Experimental investigations reveal that the mixed electrolyte (NaOH + KOH) significantly improves Material removal rate (MRR), and minimizes Overcut (OC), and Tool wear rate (TWR) compared to individual NaOH and KOH electrolytes. The study employs the Taguchi method and Grey relational analysis (GRA) to identify the ideal parameter settings that enhance machining performance. The Analysis of variance (ANOVA) results for the Grey relational grade (GRG) study indicated that voltage has the most significant effect on output responses, contributing 75.58% to the variation, followed by duty cycle at 6.02%, frequency at 2.34%, feed rate at 4.59%, and tool wp gap at 5.25%. Additionally, the regression equations were developed to determine the ideal parametric combination. This study highlights the potential of mixed electrolytes in optimizing the ECDM process for better efficiency and superior surface quality, paving the way for advancements in precision machining applications.