Analysis on the effect of ECDM process parameters during micro-machining of glass using genetic algorithm
Electro chemical discharge hybrid machining process involves in micro-machining to cut micro- channel, micro-profile as well as micro-slot, blind hole on hard materials like ceramic, quartz and glass. Experimentation has been performed using an indigenously developed micro-ECDM set up in which pressurized automated spring feeding mechanism and cam follower system is used to control the working gap. This paper emphasis to the influences of different process parameters like applied voltage (V), electrolyte concentrations (wt%), pulse frequency (Hz) and duty ratio (%) on different machining performance characteristics such as Material Removal Rate (MRR), Overcut (OC), Surface Roughness (Ra) and Heat Affected Zone (HAZ) during micro-channel cutting on glass. The empirical mathematical model has been validated by the analysis of variances. This research paper rendered the suitable optimal parametric condition during single as well as multi objective optimization using genetic algorithm (GA). Applied voltage and duty ratio has dominating role to increase MRR, OC, HAZ and surface roughness. Machining Depth increased using automated spring feeding with Cam-follower mechanism and achieved machining depth of 1.35mm. This research paper also presented the SEM analysis of micro-channel to find out the debris and other particles.