Performance Investigation of Electrochemical Micro Machining Process Using Salt Free Composite Electrolytes

The micro holes produced using electrochemical micro machining (ECMM) process emphasis the accuracy and surface finish of micro hole due to its nature of machining. Hence, this paper attempt with different salt free electrolytes and its results are compared with normal electrolyte. The electrolyte such as sodium nitrate mixed electrolyte (SONE), copper mixed electrolyte (CUME), sulfuric acid mixed electrolyte (SFAE) and mixer of these entire materials in equal ratio considered as composite electrolyte (COME) are used for experiments. The optimization techniques such as Weighted Aggregated Sum Product Assessment (WASPAS) and Multi-Objective Optimization on the basis of Ratio Analysis (MOORA) are used to determine the best machining combination. The results obtained with experiments noted that maximum MRR, i.e., 1.8887 µm/s is obtained in COME with the parameter combination of 7 V machining voltage, 90% duty cycle and 38°C electrolyte temperature which is 98.23% higher than the SONE. Furthermore, field emission scanning electron micro scope (FESEM) image analysis and energy dispersive X-ray spectroscopy (EDX) are carried out on the micro holes to know the clarity over the effect of electrolyte on surface quality of micro hole.