Experimental investigation of machined hole and o…

Journal of Materials Research and
Technology
Volume 8, Issue 5, September–October 2019, Pages 4354-4363
Original Article
Experimental investigation of machined hole and optimization of

machining parameters using electrochemical machining
T. Sathish
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https://doi.org/10.1016/j.jmrt.2019.07.046 Get rights and content

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Abstract
The electrochemical micromachining in non-conventional machining which suffers from process control
in micro level. In addition, the work material i.e. stainless steel provides high strength, high toughness and
adherence to tool material, hence machining of such material is arduous. However, the use of stainless
steel offers its availability in the field of aerospace fuel injection and orthodontic application, since it
possess superior qualities. In this paper, the optimization of micro drilling process is carried out in
stainless steel by considering certain metrics like feed rate, voltage and duty ratio. The geometric
characteristics to drill the tool depends on response parameters like overcut, removal rate of material and
conicity. Such parameter determines both the geometric and machining characteristics of the drill bit. The
study is evaluated to observe the effect of response and duty ratio parameters such as material removal rate
(MRR), machining time and overcut. Further, the conicity is analyzed using VMS images. Finally, the
proposed work establishes duty cycle in pulsed electrochemical micromachining domain of hard materials
and tests its performance.
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Keywords
Micro drilling process; Material removal rate; Stainless steel; Unconventional manufacturing
process
1. Introduction
Unconventional manufacturing process is a process assembly, which eliminates additional material using
mechanical, electrical, thermal, or chemical methods. The utilization of sharp cutting tool is avoided
strictly by the conventional manufacturing or non-traditional machining process.
The reverse process of electrochemical plating is the electro-chemical machining, which is a controlled
anodic electrochemical atomic level dissolution process. The stainless steel work-piece is conductive
electrically using a shape tool, which experiences high current flow using an electrolyte (basic or acidic),
which offers low potential difference. The anodic dissolution inside electrolyte cell is used to remove the
work-piece metal (anode) in a controlled manner using a tool (cathode). The cell passes the current, when
the electrolyte is pumped between the tool through the gap, which dissolves the work-piece metal. The
electrochemical plating is used widely in machining jobs and machining hard materials.
Various electrochemical micromachining studies involving the drilling of hole in titanium grade 2 metal
[1], stainless steel SS-316L and copper alloy CA-173 are removed with closed control loop and high
frequency voltage pulse [2]. Stainless steel [3], [4], die steel [5], Inconel grade 718, titanium grade 2 [6],
titanium grade 5 [7] (Ningsong, 2012), and stainless-steel grade 304 through polydimethylsiloxane mask
(Chen et al., 2015). Other studies involves the use of 3D micro features to produce internal grooved barrel
shaped holes [8], flat electrolyte jet machining process [9], electrode side insulation and pulse on time
diameter size (Park et al., 2008), magnetic field (Shi et al., 2002) using the action of Lorentz force and
electrical field force to form curvilinear motion result in electric current density distribution, ultra-shot
pulse [3] and finally mathematical model [10].
Various parametric influential study involves the use of precision based electrochemical micromachining
(De Silva et al., 1998) to develop narrow inter-gap electrodes. Hocheng et al. [11] proposed precision based
electrochemical machining to erode hundreds of μm on metal surface. Jain et al. [12] proposed
temperature, conductivity and current density based electrochemical machining. Further, electrochemical
micro machining studies on electrolyte flow rate, electrolyte concentration and feed rate [7], wired
electrochemical machining internal channels (Ningsong, 2012) and Taguchi L9 orthogonal array [13]. The
pulsed electrochemical machining involves prediction of minimum machining allowance [14], nickel plates
[15] and nickel based super alloy [16], very short pulses (Hyun et al., 2004), impact of pulse period and
voltage [17].
From the above review, it is found that extensive work is been applied to dissolve stainless-steel grade 2
micro drilling [18]. Further this requires higher amount of work in micro range, which is difficult to
control the electrode gap and it further deviates the machining area distribution [19]. The fabrication
electrodes is another challenge in terms of conicity, overcut, MRR and machining time consumption to
drill micro hole [20], [21]. The most work fails to address the area of variation in duty cycle and drilling of
micro hole using pulse current and this paper address this problem.
This paper involves the investigation of electrochemical micro hole drilling in titanium using parametric
optimization and studying the duty cycle influence. The main aim involves microhole drilling in stainless
steel with tungsten electrode using acidified electrolyte. It involves input parametric optimization to drill
most accurate hole and studying the effect of material removal rate (MRR), conicity, circularity, roughness
of hole surface in the work piece. Further, the duty cycle effect is studied in terms of its machining and
geometric characteristics.
2. Materials and methods
2.1. Selection of workpiece material

The workpiece is selected from pure stainless steel 304 metal and testing work piece is SS 304. The
percentage of composition of SS 304 is shown in Table 1. The sodium nitrate (NaNO3) dissolved in distilled
water is chosen as electrolyte placed in a still bath and hence during machining process, electrolyte flow is
not measured. The tool (electrode) used for drilling holes in the stainless steel sheet is copper wire. The
electrode acts as cathode during machining process with 0.5 mm diameter available as wound spool wire
been cut into small lengths and fixed in a copper tool holder.
Table 1. Compositional of SS 304.
Composition Percentage (%)
Carbon 0.08 max
Manganese 2.00 max
Phosphorus 0.045 max
Sulphur 0.030 max
Silicon 0.75 max
Chromium 18–20
Nickel 8–12
Nitrogen 0.10 max
Iron Balance
The electrochemical machining is carried out in the following setup with three subsystems, namely,
electrolytic bath and circulation system, tool feed system and inter electrode gap control system, shown in
Fig. 1.
Download : Download high-res image (199KB) Download : Download full-size image
Fig. 1. Electrochemical machine setup.
The methodology for this proposed investigation is shown in Fig. 2.

• Input parameters include pulsating power supply for ECM and inter electrode gap of 15–20 μm
diameter.
• Response parameters include conicity, MRR and overcut, where

∘ Conicity = ((DENTRY − DEXIT)/2H) × 100
where DENTRY is the hole entry diameter (μm), DEXIT is the hole exit diameter (μm) and H is the
workpiece thickness.
∘ MRR = (WB − WA)/t
where WB is the weight before work piece machining, WA is the weight after work piece machining
and t is the machining time.
∘ Overcut is the difference between mean diameter of hole at entry point and the diameter of tool.
∘ Duty ratio = TON/(TON + TOFF)

• Set 1: Duty ratio = 0.6

Fig. 2. Methodology investigation.
3. Observation
Taguchi method is used for experimental design with well-defined guidelines over special set of
orthogonal arrays. This stipulates the conduction of minimal experiments to attain full information
affecting the performance of the parameter. The orthogonal arrays choose the combination level of input
variables for each experiments, where the layout is given in Table 2.
Table 2. Orthogonal array layout.
L9 (33) orthogonal array
Independent variables Performance parameter value
Experiments Variable 1 Variable 2 Variable 3
1 1 1 1 P1
2 1 2 2 P2
3 1 3 3 P3
4 2 1 2 P4
5
5 2 2 3 P5
6 2 3 1 P6
7 3 1 3 P7
8 3 2 1 P8
9 3 3 2 P9
3.1. Experimental design

The parametric study combines Taguchi method with Grey relational method. Here, voltage, duty ratio and
feed rate is used as control variable. The parametric variation at L9 orthogonal array is shown in Table 3
Table 3. Variation of parameters.
Parameter Description Level 1 Level 2 Level 3
A Voltage (V) 16 17 18
B Feed rate (mm/min) 0.5 0.6 0.7
C Duty ratio 0.6 0.7 0.8
The response parameters is measured and shown in Table 4. The average diameter of the hole at entry and
exit places are averaged and shown in Table 5.
Table 4. Value of response parameters.
Experiment no. Voltage (V) Feed rate (mm/min) Duty ratio MRR (g/min) Overcut (mm)
L1 16 0.5 0.6 0.000002 0.565
L2 16 0.6 0.7 0.00000115 0.47
L3 16 0.7 0.8 0.00000173 0.403
L4 17 0.5 0.7 0.000001009 0.394
L5 17 0.6 0.8 0.00000171 0.375
L6 17 0.7 0.6 0.00000174 0.441
L7 18 0.5 0.8 0.00000139 0.3795
L8 18 0.6 0.6 0.00000137 0.5005
L9 18 0.7 0.7 0.00000117 0.402

Table 5. Average diameter.
Diameter at entry (mm) Diameter at exit (mm) Average diameter (mm) Conicity (mm)
1.065 0.9395 1.00225 10.45
0.97 0.7515 0.86075 18.20
0.903 0.68 0.7915 18.58
0.894 0.502 0.698 32.66
0.875 0.6605 0.76775 17.87
0.941 0.856 0.8985 7.08
0.8795 0.743 0.81125 11.37
1.0005 0.734 0.86725 22.20
0.902 0.843 0.8725 5.9
3.2. Trend analysis

The trend analysis for parametric optimization involves following parameter, namely, achieved diameter,
overcut, material removal rate and conicity. This section measures the varying parametric level with respect
to voltage, duty ratio and feed rate. This machining and geometric properties are studied using 9
experiments, where the progression of each response parameter is studied.
3.2.1. Trend of diameter

Here, the workpiece and tool does not contact each other and hence it is difficult to control the dissolution
area. From Fig. 3, it is seen that diameter increases with increased supplied current, since it increases the
dissolution rate. This is mainly due to the flushing of by products using the electrolyte, which contribute
towards the tool diameter by considering electrolyzing current and inter electrode gap.

Fig. 3. Trend of diameter.
3.2.2. Trend of overcut

The overcut phenomenon represents the material removed during electrolysis, and the results are shown
in Fig. 4. This is a non-contact process and chemical machining leads to material removal in the area and
around the electrode. Hence it leads to increase in micro hole diameter, which is called overcut, which
increases the current at TON and the values are very low. When the rate reduces, there is a convergence of
hole diameter when TOFF increase towards the tool diameter.
Fig. 4. Trend of overcut.
3.2.3. Trend of MRR

The material dissolution speed is influenced by most dominating input, shown in Fig. 5. The MRR follows
nonlinear increasing trend, which has no total agreement with electrolysis of Faraday's law due to TON
variation and narrow electrode gap. The efficiency of dissolution reduces at TON values and lower voltage.
The material erosion is gradually declined when the material dissolution occurs with lesser value and leads
to inhomogeneous conductivity distribution in electrolyte.

Fig. 5. Trend of MRR.
3.2.4. Trend of conicity

The rate of removal of metal at varying hole length is conicity, which can be termed as gap resistivity. This
affects the servo feed of the cathode tool and low charges are obtained at knife edged holes, and high
charges are obtained at straight holes reducing the hole conicity. This has increased the removed metal
ions precipitation on hole inner surface, which prevents side machining and helps in conicity reduction
(Fig. 6).
Fig. 6. Trend of conicity.
3.3. Influence of study of voltage

Voltage is the influential parameter to conduct experiments by making the parameters constant and
changing the voltage levels. The influence of MRR and machining time is studied by various experiments
conducted at different levels (16, 17 and 18 V), where the results are shown in Table 6.
Table 6. Response parameters of voltage study.
Voltage Feed rate (mm/min) Duty ratio TON TOFF Machining time MRR (g/min)
16 0.5 0.6 10 5 20:24:22 0.000002
17 0.6 0.7 14 5 17.10.07 0.00000173
18 0.7 0.8 20 5 19.30.41 0.00000117
The erosion rate of the material from the workpiece is influenced by the current passage and increasing
linearly with current. This phenomenon is due to the influence of higher current available at frontal gap
between workpiece and electrode. The machining time gets reduced when the voltage increases and this is
due to presence of higher voltage and earlier erosion, which leads to reduced machining time.
3.4. Circularity and its trend

Circularity measures the extent of machined hole deviation from the perfect circle. When the diameter is
different at entry/exit, the circularity errors are estimated at entry/exit. The circularity analyses duty ratio at
the entry/exit points. The multiple factors in electrochemical machining leads to poor examination by
circularity task. From the observation, the circularity rises and plunges into maximum if the pulse is on
time. In terms of dissolution rate, when the drilling process starts, there is a stability in material
dissolution and it gets improved when more holes are drilled.
3.5. VMS circularity analysis in drilled holes

The scanning electron microscopic images is used to examine the drilled holes, shown in Fig. 7. It is seen
that when the rate of dissolution is stabilizing the process gets steady and recast layer is seen in area due to
poor by product flushing during machining. This layer is seen clearly in second specimen and occurred
due to clogging of electrolyte with eroded SS particles and it also gets redeposited at the same time.
Fig. 7. VMS images of machined hole
4. Result and discussion

Finally, the response like overcut, MRR and conicity is measured from observed data. Finally, statistical
analysis is done over the estimated results and the signal to noise ratio for all the 3 response factor is
shown in Table 7.
Table 7. Signal to noise ratio of response parameters.

Experiment no. S/N ratio for MRR S/N ratio for overcut S/N ratio for conicity
1 −96.00 6.027 −23.93
2 −96.54 7.521 −25.72
3 −104.35 8.276 −19.27
4.1. Effect of input parameters on MRR

The effect of input parameters over MRR is shown in Table 8. It is seen that the voltage obtains the first
rank and has maximum effect on MRR, little effect on feed rate and least effect on duty ratio. The results
are plotted in Fig. 8.
Table 8. Response table of S/N ratio for MRR.
Levels Voltage (V) Feed rate (mm/min) Duty ratio
1 −96.00 −96.74 −102.14
2 −96.54 −103.80 −98.84
3 −104.35 −96.35 −95.91
Delta 8.35 7.44 6.24
Rank 1 2 3
Fig. 8. S/N ratio for MRR.
The response table of MRR is shown in Table 9. The mean ratio estimation depends on larger value of
better quality characteristics.
Table 9. Response table for mean for MRR.
1 0.000016 0.000015 0.000013
2 0.000015 0.000010 0.000011
3 0.000009 0.000015 0.000016
Delta 0.000007 0.000005 0.000005
Rank 1 2 3
It is seen from Table 9 that the voltage obtains the first rank and has maximum effect on MRR, little effect
on feed rate and least effect on duty ratio (Fig. 9).
Fig. 9. Mean for MRR.
Table 10 shows the regression analysis to estimate difference between the level 1, 2 and 3 effects on MRR,
overcut and conicity.
Table 10. Statistical regression analysis.
Predictor Coefficient SE Coefficient T P
Constant −98.9632 2.470 −40.063 0.001
Voltage 16 2.9617 3.493 0.848 0.486
Voltage 17 2.9617 3.493 0.693 0.560

Feed ratio 0.5 2.2256 3.493 0.637 0.589
Feed ratio 0.6 −4.8340 3.493 −1.384 0.301
Duty ratio 0.6 −3.1815 3.493 −0.911 0.459
Duty ratio 0.7 0.1246 3.493 0.036 0.975
S = 7.411; R2 = 72.8%; R2 (adj) = 0.0%.
4.2. Effect of input parameters on overcut

The effect of input parameters over overcut is shown in Table 12a, Table 12b. It is seen that the duty ratio
obtains the first rank and has maximum effect on duty ratio, little effect on voltage and least effect on feed
rate. The results are plotted in Fig. 10.
Fig. 10. S/N ratio for overcut.
The response table of overcut is shown in Table 11a, Table 11b. The mean ratio estimation depends on
smaller value for better quality characteristic (Fig. 11).
Table 11a. Analysis of variance for SN ratios.
Source DF Seq SS Adj SS Adj MS F P
Voltage 2 130.88 130.88 65.44 1.19 0.456
Feed rate 2 105.38 105.38 52.69 0.96 0.510
Duty ratio 2 58.45 58.45 29.22 0.53 0.259
Residual error 2 109.84 109.84 54.92
Total 8 404.54
Table 11b. Response table for mean for overcut.
1 0.4793 0.4462 0.5022
2 0.4033 0.4485 0.4220
3 0.4273 0.4153 0.3858
Delta 0.0760 0.0332 0.1163
Rank 2 3 1
Fig. 11. Mean ratio of overcut.
overcut and conicity (Table 13).
Table 12a. Statistical regression analysis for overcut vs voltage, feed rate, duty ratio.
Predictor Coefficient SE coefficient T P
Constant 7.2750 0.07235 100.549 0.000
Voltage 16 −0.8047 0.10232 −7.864 0.016
Voltage 17 0.6319 0.10232 6.176 0.025
Feed ratio 0.5 −0.1200 0.10232 −1.173 0.362
Feed ratio 0.6 −0.2452 0.10232 −2.396 0.139

Duty ratio 0.6 −1.2476 0.10232 −12.193 0.007
Duty ratio 0.7 0.2462 0.10232 2.406 0.138
S = 0.2171; R2 = 99.2%; R2 (adj) = 96.8%.
Table 12b. Response table of S/N ratio for overcut.
1 6.470 7.155 6.027
2 7.907 7.030 7.521
3 7.448 7.640 8.276
Delta 1.437 0.610 2.249
Rank 2 3 1
Table 13. Analysis of variance for SN ratios.
Voltage 2 3.2299 3.22987 1.61494 34.28 0.028
Feed rate 2 0.6237 0.62375 0.31187 6.62 0.131
Duty ratio 2 7.8595 7.85950 3.92975 83.41 0.012
Residual error 2 0.0942 0.09423 0.04711
Total 8 11.8073
4.3. Effect of input parameters on Conicity

The effect of input parameters over conicity is shown in Table 14. It is seen that the duty ratio obtains the
first rank and has maximum effect on conicity, little effect on voltage and least effect on feed rate. The
results are plotted in Fig. 12.
Table 14. Response table for S/N ratio for conicity.

1 6.470 7.155 6.027
2 7.907 7.030 7.521
3 7.448 7.640 8.276
Delta 1.437 0.610 2.249
Rank 2 3 1
Fig. 12. S/N ratio for conicity.
The response table of conicity is shown in Table 15. The mean ratio estimation depends on smaller value
of better quality characteristic (Fig. 13).
Table 15. Response table for mean for conicity.
1 15.74 18.16 13.24
2 19.20 19.42 18.92
3 13.16 10.52 15.94
Delta 6.05 8.90 5.68
Rank 2 1 3
Fig. 13. Mean for conicity.
overcut and conicity (Table 17).
Table 16. Statistical regression analysis for Conicity Vs Voltage, Feed Rate, Duty Ratio.
Predictor Coefficient SE coefficient T P
Constant −22.9719 2.291 −10.026 0.010
Voltage 16 −0.6829 3.240 −0.211 0.853
Voltage 17 −1.1359 3.240 −0.351 0.759
Feed ratio 0.5 −0.9540 3.240 −0.294 0.796
Feed ratio 0.6 −2.7517 3.240 −0.849 0.485
Duty ratio 0.6 1.5353 3.240 0.474 0.682
S = 6.873; R2 = 49.5%; R2 (adj) = 0.0%.
Table 17. Analysis of Variance for SN ratios.
Voltage 2 15.19 15.19 7.597 0.16 0.861
Feed rate 2 66.64 66.64 33.322 0.71 0.586
Duty ratio 2 10.67 10.67 5.337 0.11 0.898

Residual error 2 94.49 94.49 47.245
Total 8 187.00
The testing material attains maximum MRR, minimum over rate and reduced conicity, shown in Table 18.
Table 18. Optimum parameters for SS304.
Physical requirements Voltage (V) Feed rate (mm/min) Duty ratio
MRR 16 0.7 0.8
Overcut 16 0.6 0.6
Conicity 17 0.6 0.8
5. Conclusion
In this paper, the micro holes are drilled in pure stainless steel using fuel injector nozzle, which attains
maximum accuracy. Further, optimization of certain electrical parameters is agreed to attain optimization
of micro-hole drilling. The stainless steel work piece attains best MRR and overcut values based on central
feed rate value, duty ratio and high voltage level. The current, duty ratio and voltage response parameters
are influenced by order of independent variables influencing the response parameters is (a) current, (b)
voltage and (c) duty ratio. Further, it is observed that conicity of the micro hole is reduced considerably
from trails 1–9. Increased stability has further leads to fall in conicity and side erosion are prevented using
product accumulation. Further, the impact of duty cycle is evaluated based on response parameters like
MRR, machining time and overcut. It is seen that as the value of duty cycle increases, the machining time
has reduced and MRR remarkably increases with dissolution rate rise. The erosion rate of material
determines the convergent behaviour of tool diameter. In this study, the non-convergence exists as the
erosion increases and overcut roughness of the surface increases further, which is influenced by duty cycle
variation. With increasing erosion, the generation of extreme hydrogen bubbles increases the Ra value. The
lowered duty cycle is found, which provides improved results based on response parameters. Finally, the
pulsed electrochemical micromachining with TOFF component flushes the by-products with better surface
quality and anodic shape control.
Conflicts of interest
The authors declare no conflicts of interest.
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2. Materials and methods

2.1. Selection of workpiece material

Table 1. Compositional of SS 304.

Composition Percentage (%)

Carbon 0.08 max

Manganese 2.00 max

Phosphorus 0.045 max

Sulphur 0.030 max

Silicon 0.75 max

Nitrogen 0.10 max

Fig. 1. Electrochemical machine setup.

The methodology for this proposed investigation is shown in Fig. 2.

• Response parameters include conicity, MRR and overcut, where

∘ MRR = (WB − WA)/t

∘ Duty ratio = TON/(TON + TOFF)

• Set 2: Duty ratio = 0.7

• Set 3: Duty ratio = 0.8

Fig. 2. Methodology investigation.

Table 2. Orthogonal array layout.

L9 (33) orthogonal array

Independent variables Performance parameter value

Experiments Variable 1 Variable 2 Variable 3

3.1. Experimental design

Table 3. Variation of parameters.

Parameter Description Level 1 Level 2 Level 3

B Feed rate (mm/min) 0.5 0.6 0.7

C Duty ratio 0.6 0.7 0.8

Table 4. Value of response parameters.

L1 16 0.5 0.6 0.000002 0.565

L2 16 0.6 0.7 0.00000115 0.47

L3 16 0.7 0.8 0.00000173 0.403

L4 17 0.5 0.7 0.000001009 0.394

L5 17 0.6 0.8 0.00000171 0.375

L6 17 0.7 0.6 0.00000174 0.441

L7 18 0.5 0.8 0.00000139 0.3795

L8 18 0.6 0.6 0.00000137 0.5005

L9 18 0.7 0.7 0.00000117 0.402

1.065 0.9395 1.00225 10.45

0.97 0.7515 0.86075 18.20

0.903 0.68 0.7915 18.58

0.894 0.502 0.698 32.66

0.875 0.6605 0.76775 17.87

0.941 0.856 0.8985 7.08

0.8795 0.743 0.81125 11.37

1.0005 0.734 0.86725 22.20

0.902 0.843 0.8725 5.9

3.2. Trend analysis

3.2.1. Trend of diameter

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3.2.2. Trend of overcut

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Fig. 4. Trend of overcut.

3.2.3. Trend of MRR

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3.2.4. Trend of conicity

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