Experimental investigation of micro-machining on borosilicate glass using mist flow aided WECDM

Abstract

Wire electro-chemical discharge machining (WECDM) process is a variant of electro-chemical discharge machining process and is a novel method to machine electrically non-conductive materials. In the present research investigation, an in-house developed WECDM setup with mist flow was used to generate micro channels on borosilicate glass. The electrolyte was provided in the form of mist, formed with the combination of electrolyte and compressed air. The mist flow system was used to control the machining process that improved the stability of the spark, and flushing in the machining zone resulted in a smooth surface of machined channels. Electrolyte concentration, duty factor, wire feed rate, and mist flow rate were chosen as input process parameters, and their effect on output quality characteristics such as material removal rate and width of cut was evaluated. the performance of were during. The addition of the mist flow technique in the process resulted in an improvement in surface finish, heat affected zone (HAZ) and discharge characteristics. ANOVA analyses were carried out to obtain the significant process parameters that affected the output characteristics. Scanning electron micrograph images were captured in order to analyze the surface morphology of the machined channel and revealed thermal cracks, HAZ, irregular surface and recast layer in the samples machined with low mist flow rate as compared to samples machined using high Mist flow rates.