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

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

Process parameters	Symbols Levels
Peak current (mA)	I_p	1.2	1.35	1.5
Pulse on time (ms)	T_on	300	400	500
Duty factor	DF	0.5	0.6	0.7
Concentration of electrolyte (%)	C	15	22	5 30

[i] ECMM, electrochemical micromachining.

Magnetic field measurement of magnets using gauss meter.

Placement of magnets in the machining cycle.

Table 2

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

[i] ECMM, electrochemical micromachining; MRR, material removal rate; OC, overcut.

Methodology of TOPSIS (close to ideal solution).

Table 3

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

[i] MRR, material removal rate; OC, overcut.

Table 4

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

[i] ECMM, electrochemical micromachining.

Table 5

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

[i] ECMM, electrochemical micromachining.

Table 6

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

[i] ECMM, electrochemical micromachining.

Table 7

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

[i] MRR, material removal rate; OC, overcut.

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.

Table 8

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

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

[i] ECMM, electrochemical micromachining.

Table 9

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

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

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

References

Authors

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Articles in this issue

DOI: https://doi.org/10.2478/msp-2021-0013 | Journal eISSN: 2083-134X (formerly 2083-124X) | Journal ISSN: 2083-1331

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Language: English

Page range: 124 - 138

Submitted on: Feb 25, 2021

Accepted on: May 3, 2021

Published on: Jul 9, 2021

Published by: Wroclaw University of Science and Technology

In partnership with: Paradigm Publishing Services

Keywords:

ECMM,

overcut,

Related subjects:

Materials sciences, other,

Nanomaterials,

Functional and smart materials,

Materials characterization and properties

© 2021 T. Praveena Gopinath, J. Prasanna, C. Chandrasekhara Sastry, Sandeep Patil, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

Volume 39 (2021): Issue 1 (March 2021)

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

Figures & Tables

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Table 2

Fig. 4

Table 3

Table 4

Table 5

Table 6

Table 7

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Table 8

Table 9

Fig. 9

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