SURESH H. SUREKAR’s scientific contributions

Electrochemical machining (ECM) is a non-traditional as well as non-mechanical machining process. This is used mainly to machine hard or difficult to cut or machine materials such as Ni-base super alloys, composites, stainless steels etc. The difficulties in machining of superalloys and other hard and high strength materials by conventional processes are responsible for the development of nontraditional machining processes such as electrochemical, electrodischarge, ultrasonic etc. machining processes. The process characteristics are affected by various parameters such as electrolyte flow rate; tool feed rate; applied voltage; inter-electrode gap; current density; pH of electrolyte; concentration and temperature of electrolyte etc. In this study analysis of parameters affecting surface roughness has been carried out. The parameters considered for experimentation are: tool feed rate, electrolyte flow rate and applied voltage. Taguchi L9 orthogonal array is used for parameter setting during the experimental runs. Aqueous solution of sodium nitrate (NaNO3) is used as an electrolyte of concentration 200 g/l. The results show that good surface finish is obtained at low feed rate (0.5 mm/min), high electrolyte flow rate (350 L/hr) and high voltage (16 V). ANOVA is used to validate the results. The R Square value is above 90 % and F value positive at 95% confidence level.

Electrochemical Machining process is non-conventional, non-mechanical machining process in which material removal from the workpiece is done by means of Principle of Electrolysis. As in electrolysis in electrochemical machining two electrodes are used of which one is positive (Anode) and other is negative (Cathode). The material removal rate in electrochemical machining is determined by Faraday's Law of Electrolysis and is affected by number of the parameters controllable and non controllable. Each and every parameter is having its own effect on material removal process. Among all the parameters any one is having highest impact on the response or material removal rate and other is having less impact than the first and so on. Optimization of parameters is important in every machining process because the response or result is affected by each parameter. The parameter which has highest impact if optimized and controlled tightly then the response of the process is not deviated to the large extent. Optimization of parameters is done by designing orthogonal array and Taguchi Methodology. Principal Component is determined for getting high material removal rate.