6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18,

2016 at College
of Engineering., Pune, Maharashtra, INDIA.

Analysis of material removal and radial overcut

during micro-drilling of soda lime glass using
electrochemical discharge machining (ECDM)
Mudimallana Goud1, Apurbba Kumar Sharma2
1
Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee,
India
1
mudigoud@gmail.com
2
Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee, India
2
akshafme@iitr.ac.in

Abstract— The importance of glass has increased
significantly since the last decade, especially in the
field of microelectromechanical systems (MEMS)
because of its high scratch resistance and chemical
neutrality. The micro parts used in MEMS, such as
micro-pumps, flow sensors; drug delivery devices in
the medical field are fabricated through
micromachining. Drilling of micro-holes and
fabrication of micro-channels are the primary
machining requirements in these devices. Various
techniques are available for micromachining of glass;
but these techniques are not practiced widely owing to
limited machinability of glass. Abrasive-based
techniques, on the other hand, suffer from high tool
wear, and hence low dimensional accuracy. A
promising solution in this situation could be
electrochemical discharge machining (ECDM). In the
present work, drilling of micro-holes on soda lime
glass has been achieved using an ECDM setup
developed in-house; sodium hydroxide (NaOH) was
used as the electrolyte. The experiments were
conducted according to one-factor-at-a-time (OFAT)
method to increase the confidence limit and reliability
of the experimental data. Further, models were
developed using regression analysis (RA) and artificial
neural network (ANN) approaches to predict the
material removal rate (MRR) and the radial overcut
(ROC) during machining. The analysis of the results
shows that both the models could predict the
parameters reasonably, although the prediction using
the ANN model was marginally better than that of the
RA model for a given range of process parameters.
The comparison of the two models yielded results that
could be used in fabricating micro-channels and
drilling micro-holes on soda lime glass. The drilled
holes were further analysed using scanning electron
microscope (SEM) images.
Keywords— ECDM, OFAT, MRR, ANN, microhole
1. INTRODUCTION
The concept of electrochemical discharge
machining was presented for the first time in 1968.
Since then, this technology remained as a research
topic. The ECDM is a non-traditional machining
technology used for machining electrically non-
conducting materials like glass, ceramics, quartz, etc.
There have been significant developments on
different aspects on the process. However, owing to
the complexity of the process, it is yet to be adopted
as a full scale technology for industry; active
researches are still going on investigations issues
associated with improvement of the process.
The essential need of current competitive
industries is to enhance the quality of its machining
processes so as to maintain profitability. To meet
the industrial requirements of ECDM of glass,
extensive research is needed to improve the
performance of the ECDM process through various
optimization analyses. Several authors have
reported the optimization of quality characteristics of
ECDM process though Taguchi’s robust design ([1]-
[5]) and response surface methodology [6]. Most of
the studies were based on Taguchi with S/N ratio
analysis and grey relational analysis; a very few
reports based on multiple regression and artificial
neural network are available. The performance of
ECDM process in terms of material removal rate
(MRR) and radial overcut (ROC) can be improved by
controlling basic main process parameters, such as
applied voltage, concentration of electrolyte and
inter-electrode gap.
Several algorithms which are used for training an
ANN, the most popular one is the feed forward back
propagation (FFBP) algorithm ([7]–[8]). However, a
radial basis function (RBF) network can also be used
for training the network as it takes less time in
training and always provides global minima during
minimization of error without depending on network
weights [9]. The ECDM micro-drilling process on
ceramics has been analysed using a radial basis
function neural network (RBFNN) developed by
Shanmukhi et al. [10]. The developed network was
trained by the particle swarm optimization (PSO) and
6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18, 2016 at
College of Engineering., Pune, Maharashtra, INDIA.
genetic algorithm (GA). The comparison of GA and
PSO algorithms showed that the RBFNN model
trained by PSO performed marginally better. Die-
sinking electro-chemical spark machining (DS-ECSM)
was simulated by Panda and Yadava [11] to
establish the optimal process parameters using back
propagation neural network (BPNN) model. The
model results for material removal rate and average
surface roughness were compared with data
generated from the finite element simulation. Their
comparative observation showed that the neural
network model was predicted accurately the quality
characteristics of the DS-ECSM process. A control
strategy using the pulse classifying system based on
artificial neural network (ANN) to study the
mechanism of material removal was developed by
Mediliyegedara et al. [12]. The developed ANN
model was trained by five different activation
functions and the performance of the pulse
classification system was evaluated by quantitative
analysis of the simulated networks. They concluded
that an ANN with four inputs, five outputs and 10
neurons activated by SATLINS function could be
used in the pulse classification of ECDM process.
The results of the empirical models developed for
ECDM grooving process by Sathisha et al. [13] using
regression analysis and an ANN showed that the
results predicted by the ANN were better as
compared to the regression analysis model. Unune
and Mali [14] predicted the quality characteristics,
such as MRR and surface roughness of the electro-
discharge diamond grinding process using response
surface methodology (RSM) and ANN based
mathematical model. The ANOVA results showed
that wheel speed was the dominant factor on both
MRR and surface roughness respectively, followed
by current. The yield surface roughness magnitude
in side end milling of aluminium alloy 5083 was
predicted using feed forward neural network by
Karagiannis et al. [15]. The hyperbolic tangent
sigmoid and linear transfer functions were used for
the hidden and output layers, respectively. The
performance of the network was measured by mean
square error (MSE) and correlation between the
output values predicted by the model and the target
values. A hybrid technique of ANN along with non-
dominated sorting genetic algorithm II (NSGA-II) was
developed by Yadav and Yadava [16] for optimizing
the slotted electrical discharge abrasive grinding of
metal matrix composite. Their hybrid model ANN-
NSGA-II with ANN structure of (5-8-4-2) was capable
of generating an optimal solution for MRR and
surface roughness with good correlation between
hybrid model output and experimental data. Goud et
al. [17] reviewed the concept of mechanism of
material removal in ECDM and scopes for further
research identified. They also discussed possible
future efforts to enhance the material removal rate in
ECDM and concluded that most frequently used
electrolytes are NaOH and KOH as they are less
hazardous.
2. WORKING PRINCIPLES OF ECDM
Fig.1 shows a schematic diagram depicting the
working principle of the ECDM process. The
workpiece is dipped in an electrolyte. The tool-
electrode tip is immersed one to two millimetres in
the electrolyte and a large counter electrode is kept a
few centimetres away from the tool-electrode. The
tool-electrode submerged surface area should be
significantly smaller (usually, by a factor of about
1/100) than the counter-electrode surface. In general,
the tool-electrode is polarized as cathode and
counter-electrode as anode. A DC or a pulsed
voltage is applied between the electrodes. At an
applied voltage, typically around 25 V (lower than a
critical voltage), electrolysis occurs and consequently,
generation of oxygen bubbles results at the counter
electrode and hydrogen bubbles at the tool-electrode.
The density of the bubbles and their size can be
increased by increasing the current density. When
the increased applied voltage crosses the critical
value, the bubble coalescence starts that result in
formation of a gas film around the tool-electrode.
The gas film acts as a dielectric resistance and
creates a high potential difference between the
electrodes. As the potential difference becomes high
enough for a given pair of tool-electrolyte system,
electrical discharges do occur between the
electrolyte and the tool-electrode also called as the
discharge zone. If the workpiece is placed in the
discharge zone, machining does take place in the
form of melting, vaporization and thermal erosion
due to the heat of discharges. Further, simultaneous
chemical etching of work material also contributes to
the machining operation, although significantly less.
Fig. 1 Schematic diagram of the electrochemical discharge
machining
3. DEVELOPMENT OF SETUP
The ECDM technology remains as research topic
and was never explored seriously for industrial
applications since number of complex parameters
are involved in this process. Probably this could be
6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18, 2016 at
College of Engineering., Pune, Maharashtra, INDIA.

the reason why the ECDM machines are not readily experimental plan. In the present work, it was
available; hence, a setup was developed by considered to be helpful in predicting the unknown
integration of different parts into the required response variables (MRR and ROC) from the known
assembly as per the necessity. Fig.2 shows the variables such as applied voltage, electrolyte
schematic diagram of the homebuilt ECDM setup. concentration and inter-electrode gap. Accordingly,
the following second order regression equations
4. EXPERIMENTAL DESIGN were developed to predict the unknown variables for
For fabrication of micro-holes, the experiments were NaOH electrolyte:
designed using one-factor-at-a-time (OFAT) method
which involves testing of factors or parameters one
at a time instead of more than one or all
simultaneously to increase the confidence limit and
reliability of the experimental data. In the present
investigation, three process parameters with three
levels were used by neglecting the interaction
between them (Table 1) and other machining
conditions are shown in Table 2. Electrolyte
concentration, inter-electrode gap and applied
voltage were taken as control parameters; material
removal rate (MRR) and radial overcut (ROC) were where V, C, , and are the applied voltage,
considered as the response parameters; trials were electrolyte concentration, inter-electrode gap, and
carried out for the NaOH electrolyte. According to process error, respectively. Further, the performance
2
OFAT method, 27 trials (three factors at three levels) criterion of coefficient of determination (R ) was
were performed in the order shown in Table 3. applied to compare the developed models.
TABLE 2
MACHINING CONDITIONS

Constant parameters
Tool electrode Stainless steel
material (Cyl.: Ø 0.45 mm)
Counter electrode Graphite
material
Workpiece material Soda lime glass
Electrolyte NaOH
Level of electrolyte Approx. 1 mm above the
workpiece
Machining gap Around 25 μm
Machining time 7 min

B. ANN Model
The artificial neural network (ANN) is a powerful
modelling tool and can be used for predicting
response variables. Accordingly a 3-input and 2-
output ANN model was developed with one hidden
layer. The architecture of the ANN model is shown
Fig. 2 Schematic diagram of the homebuilt ECDM setup
in Fig.3. The ‘TRAINLM’ training function was
selected to train and the transfer function used for
TABLE I hidden layer and output layer was ‘TANSIG’. The
PROCESS PARAMETERS AND THEIR LEVELS
ANN model was trained with the experimentally
Symbol Process parameter
Level Level Level obtained data during the machining trials. The data
1 2 3 corresponding to total 27 experimental conditions
Electrolyte concentration were converted into MATLAB (v14) matrix files and
A 20 25 30
(wt%) 21 of them were chosen randomly for training the
B Inter-electrode gap (mm) 40 70 100 developed model; the remaining 6 were used for
C Applied voltage (V) 40 45 50 validation. However, the architecture was optimized
A. Regression Model prior to the predictions as different architectures
yielded different performances. In order to optimize
Multiple regression analysis was used for predicting the architecture, the ANN models were trained using
the MRR and ROC from the data obtained by OFAT
6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18, 2016 at
College of Engineering., Pune, Maharashtra, INDIA.

2
training data. The R values were computed in each
case for evaluating the performance of the neural
2 2
networks; the network with the highest R value was
2
selected. The computed values of R NaOH
electrolytes were plotted against the change in the
network as illustrated in Fig.4. The number of
neurons in the hidden layer was increased from 3 to
2
12. The maximum values of R (96.45% and 98.28%
for MRR and ROC, respectively) were obtained with
eight neurons in the hidden layer (Fig.4). It indicates
that use of higher number of neurons not necessarily
improves the performance of the network; low load
apparently pushes them to be ‘less efficient’. Hence,
it was concluded that in the present work, the ANN
architecture of 3-[8]-2 with ‘TANSIG’ transfer function
would provide the best performance to analyse and
predict the response parameters for micro-hole
drilling of soda lime glass using NaOH electrolyte.
TABLE 3
DESIGN OF EXPERIMENTS AS PER OFAT METHOD
developed for NaOH electrolyte with respect to MRR,
and ROC. The results of the models indicate that the
coefficients of determination (R ) 94.47% and
95.27% for MRR and ROC, respectively. The results
show that there is a good correlation between the
predicted values and experimentally obtained
responses. The errors in both the cases (MRR and
ROC) were within 12% (Fig.5 and 6). The reason for
the observed error explained by the fact that there
are other parameters of the ECDM process,
including tool-electrode material, electrode size and
shape, wettability of tool-electrode, feed-rate,
workpiece material, current, electrolyte, gap between
tool-electrode and workpiece, anode material, etc.,
which need to be considered for a higher degree of
correlation.

Process
Response
parameters
Trial parameters
symbols
No. -3
MRR (x10 ) ROC
A B C 3
(mm /min) (μm)
1 20 40 40 39.88 85.98
2 20 40 45 48.81 103.02 Fig. 3 Model of the ANN architecture
3 20 40 50 63.10 117.79
4 20 70 40 31.55 54.30
5 20 70 45 52.98 85.20
6 20 70 50 61.31 109.08
7 20 100 40 34.52 47.84
8 20 100 45 50.60 71.78
9 20 100 50 55.95 100.34
10 25 40 40 57.74 105.15
11 25 40 45 68.45 135.25
12 25 40 50 82.14 140.01
13 25 70 40 50.60 126.52
14 25 70 45 58.33 132.87
15 25 70 50 83.33 140.80
16 25 100 40 45.83 107.06
17 25 100 45 58.33 131.40
18 25 100 50 66.67 141.86
19 30 40 40 60.71 152.48
20 30 40 45 79.17 151.91 Fig. 4 Performance of the ANN model at different number of
neurons in the hidden layer
21 30 40 50 89.29 168.58
22 30 70 40 63.69 137.60
23 30 70 45 76.79 147.69
24 30 70 50 84.52 160.64
25 30 100 40 72.02 127.75
26 30 100 45 81.55 137.97
27 30 100 50 88.69 147.69

6. RESULTS AND DISCUSSION

A. Performance Analysis using Multiple Regression
Fig.5 and 6 shows the comparison of measured and Fig. 5 Predicted and experimental data for regression model
predicted data of multiple regression models for MRR
6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18, 2016 at
College of Engineering., Pune, Maharashtra, INDIA.

2
data. Statistically obtained R values were used to
compare the accuracy of both the models. Table 4
shows the results of the two models during validation.
The results were found to be close to the
experimental data. Hence, the proposed models can
be used to predict the MRR and ROC in ECDM
drilling process. However, it is evident from the
performance (Table 4) that the ANN model resulted
in better predicted response while compared to the
regression model.
Fig. 6 Predicted and experimental data for regression model
for ROC

B. Performance Analysis using ANN

The comparison made between the measured and
the predicted data with respect to MRR and ROC
obtained during training and testing of the ANN
model are shown in Fig.7 to 10, respectively. The
2
coefficients of determination (R ) 96.24%, 99.62%
during training and 96.55%, 93.83% during testing, Fig. 9 Predicted and experimental data for ANN model for
respectively obtained for MRR and ROC show that MRR during testing
there is a good correlation between the values of
response parameters and the predicted parameters
with maximum errors within 9.5% (Fig.7 and 8)
during training and 10.4% (Fig.9 and 10) during
testing.

Fig. 10 Predicted and experimental data for ANN model for

ROC during testing
TABLE 4
MODELS COMPARISON
2
R
Fig. 7 Predicted and experimental data for ANN model for Model Type
MRR during training
MRR ROC
Multiple Second-order 94.47% 95.27%
regression polynomial
ANN Training 96.24% 99.62%
Testing 96.55% 93.83%

Fig. 8 Predicted and experimental data for ANN model for
ROC during training
C. Overall Evaluation
An OFAT (full factorial) experimental design was
employed to study the effects of the control
parameters on MRR and ROC. Multiple regression
and artificial neural network models were developed
to predict the MRR and ROC using experimental
7. CONCLUSIONS
Modelling of the ECDM micro-drilling of soda lime
glass was carried out in the present work. The
approaches of multiple regression and artificial
neural network were used to predict MRR and ROC
in the drilled holes. The full factorial experimental
(one-factor-at-a-time) design was implemented to
conduct the experiments. The data obtained was
used to develop the MRR and ROC models. The
following major conclusions can be drawn from the
present study.
• The developed models, with multiple regression
and ANN approaches, were proved to be useful in
6th International & 27th All India Manufacturing Technology, Design and Research Conference (AIMTDR-2016), December 16-18, 2016 at
College of Engineering., Pune, Maharashtra, INDIA.
predicting the MRR and the ROC of ECDM drilled
holes.
• The ANN architecture with three neurons in input
layer, five neurons in hidden layer and two neurons
in the output layer produced the best results.
• The ANN model was found to be marginally more
accurate in predicting the process responses; it
exhibited a higher degree of correlation in terms of
2 ECDM micro-drilling process using GA-and PSO-trained
coefficient of determination (R ).
ACKNOWLEDGMENT
The authors would like to thank AICTE sponsored
quality improvement programme (QIP) for supporting
this research work.
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