Optimization of process parameters in Electro Chemical Discharge Machining of silica glass through Analysis of Means

Abstract

In recent years, the Electro Chemical Discharge Machining (ECDM) process has advanced as a substitute for machining of conductive and non-conductive materials. Optimization of the process parameters plays a crucial role in improving the quality of the processed components. The machining of microchannel in silica glass has been successfully attempted in present work by considering Analysis of Means (ANOM) of ECDM process parameters. The experiments were planned using Taguchi's L₉ orthogonal array with applied voltage, stand-off distance (SOD), electrolyte concentration (EC) and pulse on time (TON) as process parameters. The Material Removal Rate (MRR), Machining Depth (MD) and Overcut (OC) were observed as output characteristics. The ANOM study revealed that the error between experimental and predicted values of MRR, MD and OC are 4.22%, 1.92% and 3.46% respectively. Stand-off distance was found to be the most significant factor followed by pulse on time, applied voltage and electrolyte concentration from ANOVA. Confirmation test was performed by setting the optimum combination of process parameters and the predicted values from regression analysis exhibited a good agreement with experimental results.