Effect of Potassium Chloride and Potassium Sulphate Electrolyte Solutionon Surface Roughnessand Material Removal Rate in Electro Chemical Machining (ECM)
Engineering and Technology Journal,
2019, Volume 37, Issue 8A, Pages 341-347
AbstractElectrochemical machining (ECM) is nontraditional machining
which is used to remove metal by anodic dissolution. In this study the
metal workpiece (WP) was stainless steel (AISI 316) and potassium
chloride (KCl) and potassium sulphate (K2SO4) solutions were used as
electrolyte, and the tool was used from copper. In this work the
experimental parameters that used were concentration of solution,
current and voltage as input. While surface roughness (Ra) and material
removal rate (MRR) were the output. The experiments on electrochemical
machining with using concentration (10, 20 and 30) g/l, current (2, 5 and
10) A and voltage (6, 12 and 20)V. Gap size between tool and WP (0.5)
mm. The results showed that (K2SO4) solution gave surface roughness
and material removal rate less than (KCl) solution in all levels, maximum
(Ra) is (0.471) and minimum (0.049), while (KCl) solution gave
maximum (Ra) was (4.497) and minimum was (0.837). Generally
increasing in machining parameter (concentration of solution, current
and voltage) lead to increase in (Ra) and (MRR). This study aims to
compare the effect of using different electrolyte solution including
potassium chloride (KCl) and potassium sulphate (K2SO4) on the surface
roughness (Ra) and material removal rate (MRR).
 X. Fang, N. Qu, H. Li and D. Zhu, “Enhancement
of insulation coating durability in electrochemical
drilling,” Int J Adv Manuf Technol, Vol. 68, pp. 9–12,
 E.S. Lee, “International Journal of Advanced
Manufacturing Technology, Chapter 16, pp. 591-599,
 F. Phillip and O.J. Muñoz, “Manufacturing Process
and System,” Ninth edition, Chapter 20, Published
Simultaneously Canada, pp.482-483, 1997.
 R. Ganjir, “Optimization of Process Parameters in
ECM by Using Rotary U Shaped Tool,” M.Sc. Thesis,
National Institute of Technology, India, pp.1-65, 2010.
 S.J. Lee, C.P. Liu, T.J. Fan, and Y.H. Chen,
International Journal of Electrochemical Science,
Chapter 8, pp. 1713-1721 , 2013.
 M.K. Das, K. kumar and T. Kr, “Artificial Neural
Networks Modeling for the Predication of Surface
Roughness in ECM,” International Journal of Applied
Engineering Research, Vol.9, No.26, PP.9251-9254,
 Sh. Hammed, A. Mustafa and K. Safaa,
“Optimization of Surface Roughness for Al-alloy in
Electro-chemical Machining (ECM) Using Taguchi
Method,” Journal of Engineering Vol. 23, pp. 62-71,
 A.J. Unare1, P.R. Attar, “Optimaization of process
parameter of electrochemical machining of aluminum
alloy 7075 by using gray touchy,” International
Research Journal of Engineering and Technology, Vol.
 H. Al-Hofy, “Advanced Machining Process,
Nontraditional and Hybrid machining,” First Edition,
Chapter 4, McGraw-Hill Company, Egypt, pp. 77-99,
 H.H. Alwan, “Study of Some Electrochemical
Machining Characteristics of Steel Ck35,” M.Sc.
Thesis, University of Technology, Iraq, 2011.
 U. Mallick, “Estimation of MRR by using Ushape Electrode in Electrochemical Machining,” M.Sc.
Thesis, National Institute Technology, India, 2009.
 M.K. Singh, “Unconventional Manufacturing
Process,” First edition, new age international
publishers, New Delhi, 2008.
 B. Bhattacharyy, M. Malapati, J. Munda, A.
Sarkar, “Influence of tool vibration on machining
performance in electrochemical micro-machining of
copper,” Journal of material processing technology,
vol. 47, pp.335 – 342, 2007.
 U. Rath, “Two Phase Flow Analysis In
Electrochemical Machining For L-Shaped Tool,”
Department of Mechanical Engineering National
Institute of Technology Rourkela, M.Sc Thesis,
National Institute of Technology, India, pp.1-109,
- Article View: 138
- PDF Download: 175