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Energy Channelization Analysis of Rough Tools Developed by RM-MT-EDM Process during ECSM of Glass Substrates.

Tarlochan Singh1, Akshay Dvivedi2, Sarabjeet Singh Sidhu3

  • 1Department of Product and Industrial Design, Lovely Professional University, Phagwara 144001, Punjab, India.

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Rough tools significantly enhance micro-hole drilling in electrochemical spark machining (ECSM). This method improves energy channelization and reduces specific energy for efficient material removal.

Keywords:
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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Surface Engineering

Background:

  • Electrochemical spark machining (ECSM) is a micro-fabrication process.
  • Tool surface characteristics influence ECSM performance.
  • Optimizing energy delivery is crucial for efficient micro-hole drilling.

Purpose of the Study:

  • To investigate the impact of tool surface roughness on energy channelization during ECSM.
  • To analyze how rough tools affect electric field intensity and spark discharge characteristics.
  • To evaluate the resulting changes in specific energy and material removal efficiency.

Main Methods:

  • Fabrication of rough tools using rotary mode multi-tip electric discharge machining (RM-MT-EDM).
  • Electrical characterization to measure electric field intensity on tool electrodes.
  • Analysis of energy channelization index and specific energy as performance metrics in ECSM.

Main Results:

  • Rough tools increased electric field intensity by 265.54% compared to smooth tools.
  • Use of rough tools resulted in a stable gas film, leading to high-frequency spark discharges.
  • Energy channelization index improved by 248.40%, while specific energy decreased by 143.263%.

Conclusions:

  • Tool surface roughness is a critical parameter for optimizing ECSM performance.
  • Rough tools enhance energy concentration and reduce energy consumption in micro-hole fabrication.
  • The findings provide insights into improving micro-manufacturing processes through tool surface engineering.