Stray current and its consequences on microstructure of Hastelloy C-276 during parametric investigation on geometrical f
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ORIGINAL ARTICLE
Stray current and its consequences on microstructure of Hastelloy C-276 during parametric investigation on geometrical features: fabricated by electrochemical micromachining Debasish Panigrahi 1 & Sweta Rout 1 & S. K. Patel 1 & Debabrata Dhupal 2 Received: 19 March 2020 / Accepted: 5 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Micromachining is becoming most viable with assorted revamped technologies, due to their numerous ultra-rigor machining criterions. An advanced manufacturing practice like electrochemical micromachining (EMM) grips multitudinous applications with a notable demand in the advancement of microproducts like microfluidic systems, chemical reactors, and heat exchanger components. This paper justifies the channelling and drilling acts over one of the idiosyncratic super alloys, i.e. Hastelloy C-276, with a mask-less SS-304 tool electrode using NaNO3 electrolyte by EMM, to construe the impact of stray current and its consequences over the maskless electrodes and most possibly endeavour to attain dimensionally altered features. The current research work highlights to discern the effects of process criterions like pulse on/off time, electrolyte concentration, applied voltage and microtool feed rate during the perusal experimentation; a reified study over the machined surface has also been scrutinized through by means of microstructural and EDS analysis. Experiments were planned and empirical models were developed for various process parameters on output responses by endorsing response surface methodology. Validations of the models were tested and optimal sets of outputs have been found by the endorsement of multi-objective desirability–based optimization using particle swarm optimization (MOPSO). Keywords EMM . EDS . Microchannelling . Microdrilling . Microstructural analysis . MOPSO
1 Introduction The thriving insistence of process miniaturization is nowadays enticing most of the potential researchers and engineers to scrutinize the various advanced machining processes towards the micromachining techniques. It has been spread out widely in the field of manufacturing towards the production of miniaturized parts having applications in the areas of biomedicals, chemical microreactors, sensors, computers and electronics systems. Machining with conventional approach such as milling and drilling is mostly incongruous due to its stress impartment nature over work materials. Electrochemical machining (ECM), most notably electrochemical micromachining (EMM), defines itself a phenomenal competence over all the * Debabrata Dhupal [email protected] 1
Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769008, India
2
Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, 768018, India
advanced manufacturing techniques due to its growing demands for better surface integrity with defect (mostly stress, heat)-free surfaces [1–3]. During electrodischarge machining (EDM) [4] and laser-
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