الفهرس Only 14 pages are availabe for public view
 |  | from | 155 |  |  |
| | | from | 155 | | |
Abstract
The present investigation presents a study on the effect of adding fine copper and graphite conductive grains to NaCl electrolyte on the ECM performance. The effect of working parameters namely, applied voltage, feed rate, powder concentration and grain size have been studied to get its effect on; current density, metal removal rate, surface roughness, over cut and hole conicity. The results were modeled and analyzed through Response Surface Methodology (RSM). The mechanisms of metal removal using powder mixed electrolyte have been discussed. A comparison between common electrolyte and powder mixed electrolyte was also analyzed. The optimum combinations of the process parameters, in an efficient and quantitative manner, based on the developed second order response surface equations optimality searches, was obtained. The results showed the beneficial influence of powder mixed electrolyte on the improving of the metal removal rate. The experimental results reveal that adding both copper and graphite powder to the electrolyte enhance the electrolytic process, increasing the current density and the metal removal rate. The use of 20 % NaCl electrolyte leads to a surface film constituted of loosely bound particles which can easily be removed from the specimen surface by grain movement The research findings along with various mathematical models will provide an effective guideline to select parameter settings for achieving desired MRR surface roughness, over cut and hole conicity for utilizing ECM more effectively and higher accuracy.