The optimal machining parameters of electrochemical diamond drilling process: RSM approach.

Electrochemical diamond drilling (ECDD) is a novel hybrid machining process that offers an efficient solution for machining of super alloys without distressing their internal properties. The material removal process in ECDD occurs through a combination of anodic dissolution and mechanical abrasion, making it an effective solution for machining two-phase alloys that are prone to differential dissolution of phases. Ti6Al4V alloy is one such example, which has poor surface finish when electrochemically machined due to the different dissolution potentials of its α and β phases. The present study suggests the use of response surface methodology (RSM) for optimizing the ECDD process. Using central composite design (CCD), 30 experimental runs were performed to analyze the effect of input parameters—voltage, tool feed rate, concentration of electrolyte and tool RPM on material removal rate (MRR) and surface roughness (Ra). The result showed that the use of diamond abrasive tool in ECDD enhances the surface finish by removing the TiO2 layer and burrs through mechanical abrasion, while increasing MRR through electrolytic dissolution. The study found that the optimized conditions for ECDD produced an MRR of 0.041 gm/min and Ra of 3.986 µm which were 5.12% and 2.1% different from the values predicted by the regression model. The study concludes that ECDD can be used to produce high-quality surfaces on two phase alloys while preserving their internal properties, making it a valuable tool for machining of wide range of materials. [ABSTRACT FROM AUTHOR]