Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

T. Praveena Gopinath; J. Prasanna; C. Chandrasekhara Sastry; Sandeep Patil

doi:10.2478/msp-2021-0013

Figures & Tables

Experimental setup for ECMM. ECMM, electrochemical micromachining.

Magnetic field measurement of magnets using gauss meter.

Placement of magnets in the machining cycle.

Methodology of TOPSIS (close to ideal solution).

Improvement in MRR and OC in presence of magnetic field when electrochemical micromachined Ti-6Al-4V. MRR, material removal rate; OC, overcut.

EDS analysis of electrochemical micromachined Ti-6Al-4V hole profile: (A) without magnetic field and (B) with magnetic field. EDS, energy dispersive X-ray spectroscopy.

Hole profile of electrochemical micromachined Ti-6Al-4V: (A) without and (B) with magnetic field.

Atomic force microscopy of electrochemical micromachined Ti-6Al-4V hole profile: (A) without and (B) with magnetic field.

XRD analysis of electrochemical micromachined Ti-6Al-4V hole profile: (A) Without and (B) With magnetic field. XRD, x-ray diffraction.

Topographical analysis of electrochemical micromachined Ti-6Al-4V hole profile_

ECMM environment	Hole surface roughness (nm)
No magnetic field	159
Magnetic field	71

Residual stress analysis of electrochemical micromachined Ti-6Al-4V hole profile_

	No magnetic field	Magnetic field
Residual stress values (MPa)	259.62	264.89

Experimental details of ECMM setup_

System working condition
Parameters	Range
Working voltage	150 V DC
Gap voltage	0–10 V
Electrolyte	NaNO₃ + Water
Magnets	Neodymium 40 × 20 × 10 mm
Tool	Copper: ϕ 0.6 mm
Workpiece	Ti-6Al-4V: 30 × 10 × 0.1 mm

TOPSIS evaluation for ECMM of Ti-6Al-4V under nonmagnetic field_

S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	Weighted matrix		Distance from ideal solution		Closeness coefficient	Rank
S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	WMRR	WOC	Eij⁺	Eij⁻	CC_ij	Rank
1	15	1.20	300	0.5	0.08	0.09	0.05	0.03	0.36	18
2	15	1.20	300	0.5	0.08	0.09	0.05	0.03	0.37	16
3	15	1.20	300	0.5	0.08	0.09	0.05	0.03	0.36	17
4	15	1.35	400	0.6	0.13	0.10	0.02	0.06	0.78	3
5	15	1.35	400	0.6	0.13	0.10	0.02	0.06	0.78	1
6	15	1.35	400	0.6	0.13	0.10	0.02	0.06	0.78	2
7	15	1.50	500	0.7	0.10	0.09	0.04	0.03	0.48	10
8	15	1.50	500	0.7	0.10	0.09	0.04	0.03	0.48	12
9	15	1.50	500	0.7	0.10	0.09	0.04	0.03	0.48	11
10	22.5	1.20	400	0.7	0.08	0.12	0.06	0.00	0.03	25
11	22.5	1.20	400	0.7	0.08	0.12	0.07	0.00	0.00	27
12	22.5	1.20	400	0.7	0.08	0.12	0.06	0.00	0.01	26
13	22.5	1.35	500	0.5	0.10	0.09	0.04	0.04	0.50	8
14	22.5	1.35	500	0.5	0.10	0.09	0.04	0.03	0.50	9
15	22.5	1.35	500	0.5	0.10	0.09	0.03	0.04	0.51	7
16	22.5	1.50	300	0.6	0.08	0.08	0.05	0.04	0.43	15
17	22.5	1.50	300	0.6	0.09	0.08	0.05	0.04	0.43	14
18	22.5	1.50	300	0.6	0.09	0.08	0.05	0.04	0.44	13
19	30	1.20	500	0.6	0.10	0.09	0.03	0.03	0.52	4
20	30	1.20	500	0.6	0.10	0.09	0.03	0.03	0.51	5
21	30	1.20	500	0.6	0.10	0.10	0.03	0.03	0.51	6
22	30	1.35	300	0.7	0.09	0.10	0.05	0.02	0.24	24
23	30	1.35	300	0.7	0.09	0.10	0.05	0.02	0.25	23
24	30	1.35	300	0.7	0.09	0.10	0.05	0.02	0.26	22
25	30	1.50	400	0.5	0.08	0.10	0.05	0.02	0.31	21
26	30	1.50	400	0.5	0.09	0.10	0.05	0.02	0.32	19
27	30	1.50	400	0.5	0.09	0.10	0.05	0.02	0.31	20

TOPSIS evaluation for ECMM of Ti-6Al-4V under magnetic field (repulsion)_

S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	Weighted matrix		Distance from ideal solution		Closeness coefficient	Rank
S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	WMRR	WOC	Eij⁺	Eij⁻	CC_ij	Rank
1	15	1.20	300	0.5	0.05	0.08	0.11	0.05	0.30	17
2	15	1.20	300	0.5	0.05	0.08	0.11	0.05	0.31	16
3	15	1.20	300	0.5	0.05	0.08	0.11	0.05	0.30	18
4	15	1.35	400	0.6	0.16	0.10	0.02	0.11	0.82	1
5	15	1.35	400	0.6	0.16	0.10	0.03	0.11	0.82	2
6	15	1.35	400	0.6	0.16	0.10	0.03	0.11	0.81	3
7	15	1.50	500	0.7	0.11	0.09	0.06	0.07	0.54	11
8	15	1.50	500	0.7	0.11	0.09	0.06	0.07	0.53	12
9	15	1.50	500	0.7	0.11	0.09	0.06	0.07	0.54	10
10	22.5	1.20	400	0.7	0.06	0.12	0.11	0.01	0.05	25
11	22.5	1.20	400	0.7	0.06	0.13	0.12	0.01	0.04	27
12	22.5	1.20	400	0.7	0.06	0.12	0.11	0.01	0.05	26
13	22.5	1.35	500	0.5	0.11	0.08	0.05	0.07	0.57	9
14	22.5	1.35	500	0.5	0.11	0.09	0.05	0.07	0.57	8
15	22.5	1.35	500	0.5	0.11	0.09	0.05	0.07	0.57	7
16	22.5	1.50	300	0.6	0.06	0.08	0.10	0.05	0.32	13
17	22.5	1.50	300	0.6	0.06	0.08	0.10	0.05	0.32	15
18	22.5	1.50	300	0.6	0.06	0.08	0.10	0.05	0.32	14
19	30	1.20	500	0.6	0.12	0.09	0.05	0.07	0.60	4
20	30	1.20	500	0.6	0.12	0.09	0.05	0.07	0.58	6
21	30	1.20	500	0.6	0.12	0.10	0.05	0.07	0.58	5
22	30	1.35	300	0.7	0.07	0.11	0.10	0.03	0.22	21
23	30	1.35	300	0.7	0.07	0.11	0.10	0.03	0.21	24
24	30	1.35	300	0.7	0.07	0.11	0.10	0.03	0.21	23
25	30	1.50	400	0.5	0.06	0.10	0.10	0.03	0.23	20
26	30	1.50	400	0.5	0.06	0.10	0.10	0.03	0.23	19
27	30	1.50	400	0.5	0.06	0.10	0.10	0.03	0.22	22

TOPSIS evaluation for ECMM of Ti-6Al-4V under magnetic field (attraction)_

S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	Weighted matrix		Distance from ideal solution		Closeness coefficient	Rank
S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	WMRR	WOC	Eij⁺	Eij⁻	CC_ij	Rank
1	15	1.20	300	0.5	0.07	0.08	0.09	0.05	0.34	16
2	15	1.20	300	0.5	0.07	0.08	0.09	0.04	0.34	17
3	15	1.20	300	0.5	0.07	0.08	0.09	0.04	0.33	18
4	15	1.35	400	0.6	0.16	0.10	0.02	0.09	0.82	1
5	15	1.35	400	0.6	0.16	0.10	0.02	0.09	0.80	3
6	15	1.35	400	0.6	0.16	0.10	0.02	0.09	0.82	2
7	15	1.50	500	0.7	0.09	0.09	0.07	0.04	0.40	10
8	15	1.50	500	0.7	0.09	0.09	0.07	0.04	0.40	11
9	15	1.50	500	0.7	0.09	0.09	0.07	0.04	0.40	12
10	22.5	1.20	400	0.7	0.07	0.13	0.10	0.00	0.03	26
11	22.5	1.20	400	0.7	0.07	0.13	0.10	0.00	0.03	27
12	22.5	1.20	400	0.7	0.07	0.12	0.10	0.00	0.03	25
13	22.5	1.35	500	0.5	0.10	0.09	0.06	0.05	0.43	8
14	22.5	1.35	500	0.5	0.09	0.09	0.07	0.05	0.41	9
15	22.5	1.35	500	0.5	0.10	0.08	0.06	0.05	0.44	6
16	22.5	1.50	300	0.6	0.08	0.08	0.08	0.05	0.37	14
17	22.5	1.50	300	0.6	0.08	0.08	0.08	0.05	0.37	15
18	22.5	1.50	300	0.6	0.08	0.08	0.08	0.05	0.37	13
19	30	1.20	500	0.6	0.10	0.09	0.06	0.05	0.45	5
20	30	1.20	500	0.6	0.10	0.09	0.06	0.05	0.44	7
21	30	1.20	500	0.6	0.10	0.09	0.06	0.05	0.46	4
22	30	1.35	300	0.7	0.08	0.11	0.08	0.02	0.21	22
23	30	1.35	300	0.7	0.08	0.11	0.08	0.02	0.21	23
24	30	1.35	300	0.7	0.08	0.11	0.08	0.02	0.22	21
25	30	1.50	400	0.5	0.08	0.10	0.09	0.03	0.25	20
26	30	1.50	400	0.5	0.08	0.10	0.08	0.03	0.26	19
27	30	1.50	400	0.5	0.08	0.10	0.09	0.02	0.20	24

Computational steps of SIMOS weighting procedure_

Subset criteria	Number of criteria (variables)	Number of position	Non-normalized weighted matrix	Total (%)
MRR	1	1	1/2*100 = 50~50	50
OC	1	2	11/2*100 =50~50	50

Orthogonal array experiment (L27) for magnetic and nonmagnetic field ECMM of Ti-6Al-4V titanium alloy_

					No magnetic force		Attraction magnetic force		Repulsion magnetic force
S. No.	Concentration of electrolyte (g/l)	Ip (A)	Ton (μs)	DF	MRR 10⁻³ (mm³/min)	OC (mm)	MRR 10⁻³ (mm³/min)	OC (mm)	MRR 10⁻³ (mm³/min)	OC (mm)
1	15	1.20	300	0.5	0.59	0.32	0.66	0.25	0.72	0.21
2	15	1.20	300	0.5	0.59	0.32	0.66	0.25	0.73	0.21
3	15	1.20	300	0.5	0.59	0.32	0.66	0.26	0.73	0.22
4	15	1.35	400	0.6	0.97	0.35	1.48	0.31	2.22	0.28
5	15	1.35	400	0.6	0.97	0.35	1.47	0.31	2.22	0.28
6	15	1.35	400	0.6	0.96	0.35	1.47	0.31	2.21	0.28
7	15	1.50	500	0.7	0.72	0.33	0.88	0.28	1.46	0.24
8	15	1.50	500	0.7	0.72	0.33	0.88	0.28	1.46	0.24
9	15	1.50	500	0.7	0.72	0.33	0.87	0.28	1.47	0.24
10	22.5	1.20	400	0.7	0.60	0.43	0.68	0.39	0.78	0.34
11	22.5	1.20	400	0.7	0.59	0.43	0.68	0.39	0.79	0.35
12	22.5	1.20	400	0.7	0.59	0.43	0.68	0.39	0.79	0.34
13	22.5	1.35	500	0.5	0.72	0.32	0.89	0.27	1.50	0.23
14	22.5	1.35	500	0.5	0.73	0.32	0.87	0.27	1.52	0.24
15	22.5	1.35	500	0.5	0.73	0.32	0.89	0.26	1.51	0.23
16	22.5	1.50	300	0.6	0.62	0.30	0.72	0.24	0.85	0.22
17	22.5	1.50	300	0.6	0.62	0.30	0.72	0.24	0.85	0.22
18	22.5	1.50	300	0.6	0.62	0.29	0.72	0.24	0.84	0.22
19	30	1.20	500	0.6	0.76	0.34	0.97	0.29	1.60	0.26
20	30	1.20	500	0.6	0.76	0.34	0.95	0.29	1.57	0.26
21	30	1.20	500	0.6	0.77	0.34	0.96	0.28	1.59	0.26
22	30	1.35	300	0.7	0.64	0.37	0.78	0.34	1.00	0.30
23	30	1.35	300	0.7	0.64	0.37	0.78	0.34	0.99	0.30
24	30	1.35	300	0.7	0.65	0.37	0.78	0.34	0.99	0.30
25	30	1.50	400	0.5	0.62	0.35	0.70	0.31	0.82	0.26
26	30	1.50	400	0.5	0.63	0.35	0.73	0.31	0.84	0.26
27	30	1.50	400	0.5	0.62	0.35	0.71	0.33	0.83	0.27

Improvement in response factors in presence of magnetic field with respect to nonmagnetic field electrochemical micromachined Ti-6Al-4V_

				% Increase in MRR	% Decrease in OC
Concentration of electrolyte (g/l)	Ip(A)	Ton (μs)	DF	Attraction	Repulsion	Concentration of electrolyte (g/l)	Ip(A)	Ton (μs)
15	1.20	300	0.5	12.09	23.51	15	1.20	300
15	1.20	300	0.5	11.91	23.74	15	1.20	300
15	1.20	300	0.5	12.44	23.95	15	1.20	300
15	1.35	400	0.6	52.43	127.99	15	1.35	400
15	1.35	400	0.6	51.47	128.19	15	1.35	400
15	1.35	400	0.6	51.99	129.68	15	1.35	400
15	1.50	500	0.7	22.45	103.00	15	1.50	500
15	1.50	500	0.7	22.39	103.34	15	1.50	500
15	1.50	500	0.7	21.78	103.98	15	1.50	500
22.5	1.20	400	0.7	14.05	31.28	22.5	1.20	400
22.5	1.20	400	0.7	16.12	35.21	22.5	1.20	400
22.5	1.20	400	0.7	14.88	33.62	22.5	1.20	400
22.5	1.35	500	0.5	23.30	107.71	22.5	1.35	500
22.5	1.35	500	0.5	20.56	110.10	22.5	1.35	500
22.5	1.35	500	0.5	20.53	106.00	22.5	1.35	500
22.5	1.50	300	0.6	15.51	37.78	22.5	1.50	300
22.5	1.50	300	0.6	15.23	36.32	22.5	1.50	300
22.5	1.50	300	0.6	16.34	35.64	22.5	1.50	300
30	1.20	500	0.6	27.78	110.54	30	1.20	500
30	1.20	500	0.6	25.28	107.33	30	1.20	500
30	1.20	500	0.6	25.00	107.12	30	1.20	500
30	1.35	300	0.7	22.18	55.34	30	1.35	300
30	1.35	300	0.7	20.46	53.08	30	1.35	300
30	1.35	300	0.7	20.13	51.27	30	1.35	300
30	1.50	400	0.5	14.18	33.51	30	1.50	400
30	1.50	400	0.5	15.97	33.52	30	1.50	400
30	1.50	400	0.5	14.28	32.43	30	1.50	400

Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

Figures & Tables

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Topographical analysis of electrochemical micromachined Ti-6Al-4V hole profile_

Residual stress analysis of electrochemical micromachined Ti-6Al-4V hole profile_

Experimental details of ECMM setup_

TOPSIS evaluation for ECMM of Ti-6Al-4V under nonmagnetic field_

TOPSIS evaluation for ECMM of Ti-6Al-4V under magnetic field (repulsion)_

TOPSIS evaluation for ECMM of Ti-6Al-4V under magnetic field (attraction)_

Computational steps of SIMOS weighting procedure_

Orthogonal array experiment (L27) for magnetic and nonmagnetic field ECMM of Ti-6Al-4V titanium alloy_

Improvement in response factors in presence of magnetic field with respect to nonmagnetic field electrochemical micromachined Ti-6Al-4V_

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