Group 1 Ecm Ppt 5 (1) - Copy.pptx

MGM’s College of Engineering & Technology, Noida

Project Presentation 6 on

“FABRICATION OF ECM” Under the supervision of: Mr. Abhijit Kulkarni (Assistant Professor)

Submitted by: Sunil Kumar(1509540063) Akash Pal(1509540005) Anupam kr. Singh(1509540014) Md. Ashif(1409540035)

Content  Introduction

 Fabricated parts of ECM

 Literature Review

 Work done so far

 Objective & Motivation

 Future works

 Setup of ECM

 References

 Process Parameters  Pump and transformer  Methodology used

Introduction  Electrochemical Machining (ECM) is a nontraditional machining process, Which is opposite of

electrochemical or galvanic coating.  Working Principle:-

ECM works on the principle of Faraday law of electrolysis in which ions are displaced from work

piece.

Literature Review Sr.No .

Author

Input

Output

Conclusion

1

A. Mohanty, Gangadharudu Talla, S. Dewangan (2014)

concentration of MRR electrolyte, voltage, feed rate, electrode gap

2

Tingyu Xue (2016)

Work piece Surface The cathode material Tool Roughness feed rate could material be increased to Electrolyte improve surface roughness.

The MRR increased with increase in voltage

Objectives:Fabrication of ECM machine. Analysis of variation of output on different input parameters.

Motivation:Curiosity to know the detail working of ECM. Machining at low power input.

Setup of ECM

Process Parameters Sr. No.

Input Parameter

Output Parameter

1

Tool gap

Small Medium Large

2

Electrolyte concentration Electrode material Electrolyte type

Molarity bases

3 4

Copper, brass, bronze NaCl, KOH, NaNo3

MRR, Surface finish

Transformer

Pump Working

principle

is INPUT

centrifugal type.

Frequency = 50 Hz

Power consume = 0.035 kw

Voltage

= 220 volt

Voltage = 220 Volt.

Current

= 1.67 amp.

Total head = 1.5 meter.

(alternate current)

Material of the pump is OUTPUT

Teflon (C2F4)n .

Voltage

Flow rate through the pump Current = 1800 LPM.

= 24 volt = 25 amp.

(direct current)

Methodology Used Literature review

Assembly of parts

Experimentation

Market survey

Fabrication & Purchase of parts

Testing & validation

Conceptual design & drawing

Selection of material

Optimization & documentation

Fabricated Parts of ECM Machine

Stand Structure

Fabrication of Table

Electrolyte tank

Machining Tank

Tool Holder

Complete Structure

Work Done After 4th Presentation Drilling and filing in tank Tap fitting Salt measuring Electrolyte Solution prepared Wiring of ECM machine Discharge measuring through pipe Electrode grooving & facing Testing of ECM

Complete Assembly of ECM

Molarity Concentration NaCl solution Molecular weight = 23+35 = 58 g/mol Weight of the salt = 250 g Volume of solution = 15 liters No. of moles = weight/ molecular weight = 250/58 = 4.3 mole Molarity conc. = No. of moles/ volume = 4.3/15 = 0.286

Circuit Diagram of ECM

Pump Actual Discharge Pump discharge has been measured on 15 liters of water. Volume of liquid = 15 liters Time taken to pump water from electrolyte tank to machining tank = 40 second Discharge = (vol. of liquid pump) ÷ (time taken) = 15 ÷ 40 = 0.375 liter/sec = 0.000375 cubic meter per sec.

Work-piece before machining

Work-piece after machining

Work-piece after machining

Work done so Far  Complete ECM Setup  Testing  Salt Concentration

ECM Setup

Test on Al by copper tool

Copper Tool

Al Sheet

Machining

Test on Al by brass tool

Brass tool

Al Sheet

Salt Concentration NaCl solution Molecular weight = 23+35 = 58 g/mol Weight of the salt = 300 g Volume of solution = 18 liters No. of moles = weight/ molecular weight = 300/58 = 5.17 mole Molarity conc. = No. of moles/ volume = 5.17/18 = 0.287

Test on GI sheet by brass tool

Brass Tool

GI Sheet

Test on GI sheet by copper tool

Copper Tool

GI Sheet

Test on GI sheet by copper tool

Copper Tool

GI Sheet

Test on GI sheet by hollow copper tool

Hollow Copper Tool

GI Sheet

Salt Concentration NaCl solution Molecular weight = 23+35 = 58 g/mol Weight of the salt = 250 g Volume of solution = 15 liters No. of moles = weight/ molecular weight = 250/58 = 4.3 mole Molarity conc. = No. of moles/ volume = 4.3/15 = 0.286

Future Work Testing and validation.

References [1] Mohan Kumar, (2016) Electrochemical Machining: Review Of Historical And Recent Development,vol no. 5 issue no. 03. [2] K.P. Rajurkar, M.M. Sundaram, (march 2013) Review of Electrochemical The Seventeenth CIRP Conference on ElectroPhysical and Chemical Machining(ISEM). [3] Adam Ruszaj (2014) A sequential electrochemical-electro discharge process for micro part manufacturing, Precision Engineering, 38, 680–690.

Thank you