Monel 400 is a cuprous nickel alloy which is very well-known for its resistivity towards physical and chemical strength. It is probably one of the hardest and most non-corrosive materials known in industrial as well as research field. These properties have enhanced its applications in various fields such as aerospace industries, marine industries, automotive industries etc. Monel 400 alloys are too hard to machine using conventional machine tools and methods as it work hardens rapidly on its surface. Authors concluded that electrochemical machining is the choice of machining of these materials. The present work is carried out to analyze the impact of ECM process parameters such as applied voltage (V), inter-electrode gap (IEG) and electrolyte concentration (EC) on material removal rate (MRR) and surface roughness (Ra). An aqueous sodium nitrate (NaNO3) is used as basic electrolyte in the electrochemical machining of Monel 400 alloys. Response surface methodology (RSM) based central composite design (CCD) is used as experimental strategy. Effects of process parameters as well as their interactions are analysed and the process parameters are optimized.

Venkatachalam G

Mechanical

School of Mechanical Engineering

Chennai Campus

Kalaimathi M

Makhijani N

Agrawal A

Sivakumarz M.

Vellore Institute of Technology (VIT) is a private university located in&nbsp;Tamil Nadu, India. Founded in 1984, as Vellore Engineering College, the institution offers 20 undergraduate, 34 postgraduate, four integrated and four research programs. It has campuses in Vellore, Amravati, Bhopal and Chennai.

VIT is one of the top ranked private universities in India according to NIRF, THE and QS Rankings.&nbsp;Govt. of India has recognized&nbsp;VIT, Vellore as an&nbsp;Institution of Eminence. This has allowed VIT to take independent quality initiatives and move up in world ranking.

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VIT University

Applied Mechanics and Materials

Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science

Electrochemical machining of 20MnCr5 alloy steel with magnetic flux assisted vibrating tool

Machining of nickel alloys, particularly Monel 400 alloys, plays an important role in numerous applications of aircraft and marine industries. Machining of these alloys, with complicated shapes, through conventional machine tools is a cumbersome task. Therefore, an experimental research was made to investigate the travelling-wire electrochemical machining (TWECM) characteristics of Monel 400 alloys. TWECM has the benefit of negligible tool wear and stress-free machining. The improper removal of contaminants, mostly oxides on the specimen surface, reduces the performance of TWECM. In this direction, ozonated aqueous NaCl was used as an electrolyte in order to enhance the machining performance of TWECM. The predominant TWECM process parameters i.e. applied voltage (V), electrolyte concentration (EC) and electrolyte flow rate (U) were considered to investigate the performance measures of material removal rate (MRR) and surface roughness (Ra). The microstructure of surface of the Monel 400 alloys specimen machined with TWECM was studied to understand the effect of electrolyte during the machining. Maximum of 90% increase in MRR was observed because of this new electrolyte. The surface roughness was also decreased considerably up to 32%. The contour plots were drawn to study the individual and interactive effect of process parameters on performance measures. © 2017, The Brazilian Society of Mechanical Sciences and Engineering.

Journal of the Brazilian Society of Mechanical Sciences and Engineering

Experimental investigation on the suitability of ozonated electrolyte in travelling-wire electrochemical machining

Procedia CIRP

Review of Electrochemical and Electrodischarge Machining

Journal of Advanced Mechanical Engineering

Linear Modeling of the Electrochemical Machining Process Using Full Factorial Design of Experiments

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Experimental investigation on die corner accuracy for wire electrical discharge machining of Monel 400 alloy

The International Journal of Advanced Manufacturing Technology

Study of electrochemical machining characteristics of Al/SiCp composites

Portugaliae Electrochimica Acta

Selection of Optimum Parameters in Non Conventional Machining of Metal Matrix Composite

Investigations on Machining of Monel 400 Alloys Using Electrochemical Machining with Sodium Nitrate as Electrolyte

Journal	Applied Mechanics and Materials
Publisher	Trans Tech Publications, Ltd.
ISSN	16609336
Open Access	No