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<p>Electrochemical Discharge Machining (ECDM) is a hybrid micromachining technique that combines the principles of Electric Discharge Machining (EDM) and Electrochemical Machining (ECM), and has been widely used by researchers to address the limitations of conventional and non-conventional methods for machining of non-conductive materials. In the present study, a customized in-house rotary-type ECDM setup was developed and used to machine E-glass fiber epoxy composite –materials extensively used in aerospace, automotive, marine, and electronic applications. The input parameters considered were applied voltage, electrolyte concentration, inter-electrode gap, tool feed rate, and tool rotation speed. The responses evaluated were material removal rate (MRR), overcut, and circularity error. Experimental results revealed that applied voltage and electrolyte concentration were the most influential parameters affecting MRR, contributing 84% and 11% respectively. While higher voltage and concentration improved MRR, they also led to increased overcut. Tool rotation was found to be effective in enhancing circularity accuracy. Additionally, the successful fabrication of microchannels demonstrated the feasibility of using rotary-type ECDM process for fabricating precise micro-features, making it a promising technique for applications in lightweight structures, microsensors, PCBs, and microfluidic devices. This study provide a foundational for future research aimed at optimizing electrolyte formulations and improving the quality of machined features.</p>

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Experimental investigation to develop micro-features on e-glass fiber epoxy composite using rotary electrochemical discharge machining

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月2日

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  • Sourav P S,
  • Priyaranjan Sharma,
  • Anup Malik

摘要

Electrochemical Discharge Machining (ECDM) is a hybrid micromachining technique that combines the principles of Electric Discharge Machining (EDM) and Electrochemical Machining (ECM), and has been widely used by researchers to address the limitations of conventional and non-conventional methods for machining of non-conductive materials. In the present study, a customized in-house rotary-type ECDM setup was developed and used to machine E-glass fiber epoxy composite –materials extensively used in aerospace, automotive, marine, and electronic applications. The input parameters considered were applied voltage, electrolyte concentration, inter-electrode gap, tool feed rate, and tool rotation speed. The responses evaluated were material removal rate (MRR), overcut, and circularity error. Experimental results revealed that applied voltage and electrolyte concentration were the most influential parameters affecting MRR, contributing 84% and 11% respectively. While higher voltage and concentration improved MRR, they also led to increased overcut. Tool rotation was found to be effective in enhancing circularity accuracy. Additionally, the successful fabrication of microchannels demonstrated the feasibility of using rotary-type ECDM process for fabricating precise micro-features, making it a promising technique for applications in lightweight structures, microsensors, PCBs, and microfluidic devices. This study provide a foundational for future research aimed at optimizing electrolyte formulations and improving the quality of machined features.