The significance of uniformity and surface quality is highlighted by recent advancements in the fabrication of holes on glass materials, particularly for industrial applications of the electrochemical discharge drilling (ECDD) process. Nevertheless, the problem of inadequate electrolyte in the hydrodynamic area prevents the process of drilling which further results into a high hole tapering and poor depth. The present research explores the application of magnetic-assisted electrochemical discharge drilling (M-ECDD) to produce holes on a glass material using a closed-loop system of adaptive tool feed method, implemented to prevent the tool contacts with the glass material. The comparative analysis of the hole taperness (HT), machining depth (MD), surface roughness (SR), and material removal rate (MRR) is carried out with and without magnetic effect. Moreover, the effect of various input parameters on hole characteristics is studied. It is observed that the magnetic field regulates bubble formation and detachment, improving the ECDD process. Lorentz forces affect bubble behavior and film stability, resulting in magnetohydrodynamic (MHD) convection which forces the electrolyte to travel at higher depths, improving electrolyte circulation and discharge frequency. An improvement of 14.86%, 58.14%, 32.71%, and 23.89% in MD, HT, SR, and MRR is observed with the application of the magnetic field.

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Enhancing Hole Characteristics During Magnetic Assistance Closed-Loop Electrochemical Discharge Drilling (M-CLECDD)

  • Viveksheel Rajput,
  • Sarbjit Singh,
  • Perminderjit Singh

摘要

The significance of uniformity and surface quality is highlighted by recent advancements in the fabrication of holes on glass materials, particularly for industrial applications of the electrochemical discharge drilling (ECDD) process. Nevertheless, the problem of inadequate electrolyte in the hydrodynamic area prevents the process of drilling which further results into a high hole tapering and poor depth. The present research explores the application of magnetic-assisted electrochemical discharge drilling (M-ECDD) to produce holes on a glass material using a closed-loop system of adaptive tool feed method, implemented to prevent the tool contacts with the glass material. The comparative analysis of the hole taperness (HT), machining depth (MD), surface roughness (SR), and material removal rate (MRR) is carried out with and without magnetic effect. Moreover, the effect of various input parameters on hole characteristics is studied. It is observed that the magnetic field regulates bubble formation and detachment, improving the ECDD process. Lorentz forces affect bubble behavior and film stability, resulting in magnetohydrodynamic (MHD) convection which forces the electrolyte to travel at higher depths, improving electrolyte circulation and discharge frequency. An improvement of 14.86%, 58.14%, 32.71%, and 23.89% in MD, HT, SR, and MRR is observed with the application of the magnetic field.