Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material
Many microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and br...
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MDPI AG
2021-05-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/14/9/2377 |
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| author | Ankit D. Oza Abhishek Kumar Vishvesh Badheka Amit Arora Manoj Kumar Catalin I. Pruncu Tej Singh |
| author_facet | Ankit D. Oza Abhishek Kumar Vishvesh Badheka Amit Arora Manoj Kumar Catalin I. Pruncu Tej Singh |
| author_sort | Ankit D. Oza |
| collection | DOAJ |
| description | Many microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and brittleness. The key objective of the current study was to demonstrate the fabrication of microslits on quartz material through a magnetohydrodynamics (MHD)-assisted traveling wire-electrochemical discharge micromachining process. Hydrogen gas bubbles were concentrated around the entire wire surface during electrolysis. This led to a less active dynamic region of the wire electrode, which decreased the adequacy of the electrolysis process and the machining effectiveness. The test results affirmed that the MHD convection approach evacuated the gas bubbles more rapidly and improved the void fraction in the gas bubble scattering layer. Furthermore, the improvements in the material removal rate and length of the cut were 85.28% and 48.86%, respectively, and the surface roughness was reduced by 30.39% using the MHD approach. A crossover methodology with a Taguchi design and ANOVA was utilized to study the machining performance. This exploratory investigation gives an unused strategy that shows a few advantages over the traditional TW-ECDM process. |
| first_indexed | 2024-03-10T11:44:15Z |
| format | Article |
| id | doaj.art-5e37cf3574524e548a856bbe3ff6b795 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T11:44:15Z |
| publishDate | 2021-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-5e37cf3574524e548a856bbe3ff6b7952023-11-21T18:14:57ZengMDPI AGMaterials1996-19442021-05-01149237710.3390/ma14092377Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz MaterialAnkit D. Oza0Abhishek Kumar1Vishvesh Badheka2Amit Arora3Manoj Kumar4Catalin I. Pruncu5Tej Singh6Industrial Engineering Department, Pandit Deendayal Energy University, Gandhinagar 382007, IndiaIndustrial Engineering Department, Pandit Deendayal Energy University, Gandhinagar 382007, IndiaMechanical Engineering Department, Pandit Deendayal Energy University, Gandhinagar 382007, IndiaMaterials Engineering, Indian Institute of Technology, Gandhinagar-382355, IndiaProduction & Industrial Engineering Department, Punjab Engineering College, Chandigarh 160012, IndiaMechanical Engineering, Imperial College London, Exhibition Rd., London SW7 2AZ, UKSavaria Institute of Technology, ELTE Eötvös Loránd University, 9700 Szombathely, HungaryMany microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and brittleness. The key objective of the current study was to demonstrate the fabrication of microslits on quartz material through a magnetohydrodynamics (MHD)-assisted traveling wire-electrochemical discharge micromachining process. Hydrogen gas bubbles were concentrated around the entire wire surface during electrolysis. This led to a less active dynamic region of the wire electrode, which decreased the adequacy of the electrolysis process and the machining effectiveness. The test results affirmed that the MHD convection approach evacuated the gas bubbles more rapidly and improved the void fraction in the gas bubble scattering layer. Furthermore, the improvements in the material removal rate and length of the cut were 85.28% and 48.86%, respectively, and the surface roughness was reduced by 30.39% using the MHD approach. A crossover methodology with a Taguchi design and ANOVA was utilized to study the machining performance. This exploratory investigation gives an unused strategy that shows a few advantages over the traditional TW-ECDM process.https://www.mdpi.com/1996-1944/14/9/2377electrolytemachiningmicroslitsMHDMRRroughness |
| spellingShingle | Ankit D. Oza Abhishek Kumar Vishvesh Badheka Amit Arora Manoj Kumar Catalin I. Pruncu Tej Singh Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material Materials electrolyte machining microslits MHD MRR roughness |
| title | Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material |
| title_full | Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material |
| title_fullStr | Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material |
| title_full_unstemmed | Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material |
| title_short | Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material |
| title_sort | improvement of the machining performance of the tw ecdm process using magnetohydrodynamics mhd on quartz material |
| topic | electrolyte machining microslits MHD MRR roughness |
| url | https://www.mdpi.com/1996-1944/14/9/2377 |
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