Modelling and simulation of MRR in electro-chemical surface grinding of Al-SiC-Gr using hybrid analytical approach

Abstract

Electro-Chemical Surface Grinding (ECSG) is a hybrid machining process which utilizes synergic actions of three sub-processes viz. electrochemical dissolution, grinding action of abrasive particles and erosive action of electrolyte flow in inter electrode gap. Since, occurrence of turbulence in machining zone significantly affects the machining performance, it is required to analyze the turbulence phenomenon in ECSG process. The exact solution and Numerical solution–based hybrid analytical approach has been used to predict the Material Removal Rate (MRR) in ECSG of Al-SiC-Gr. In this model, the streaming potential of electrolytic action, abrasive action of grinding wheel and shear force of electrolyte flow between inter electrode gap have been considered. Finite Element Method based Numerical modelling has been carried out to analyze the electrolyte flow in machining zone in order to evaluate the MRR due to erosive action. It was observed that the application of shear force on oxide layer rises with the increase in flow rate of electrolyte. Confirmation experiment has been performed to validate the modelling results. Validation results show a minor error of 8.21% in prediction of MRR using analytical as well as finite element model.