Pimpri Chinchwad Education Trust’s

Pimpri Chinchwad College of Engineering

An Autonomous Institute affiliated to SPPU

Title of Project: Design & development of system for continuous flow of electrolyte in
electrochemical micromachining

Guide Name: G.D.Kale​ Group ID : 1

Group Members
1) Prathamesh Khade– 120B1G175
2) Aniket Kambale – 120B1G171
3) Nukul Meshram – 120B1G180
4) Bassaam Khan - 120B1G207

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 Overview of Presentation
1) Introduction
9) Experimental Investigation
2) Need of the project
3) Objectives 10) Results and Discussion
4) Scope 11) Conclusion
5) Problem Definition
12) Future Scope
6) Literature referred
7) Methodology Planned 13)Time Activity Chart
8) Design Calculations 14)References/Appendix

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Problem Definition
The proposed project focused on the detailed analysis and development of continuous flow of electrolyte. The

problem statement to carry out the project work is defined as, “Design & development of systems for continuous

flow of electrolyte in electrochemical micromachining”.

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Introduction
Components

• Tank

• Pipe

• Filter

• Pump

• Valve

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Objectives

1. DESIGNING A 2. NUMERICAL STUDIES OF 3. FLOW ANALYSIS OF

CONTAINER FOR VELOCITY AND DISCHARGE ELECTROLYTE.
ELECTROLYTE. OF ELECTROLYTE.

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Scope
In this project, the focus is on designing and implementing the continuous flow of electrolyte. The analysis is
conducted both analytically and numerically. The flow rate of electrolyte will be estimated for required
efficient machining.

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Need of the project
❖ Increase the reusability of electrolytes.

❖ Cost Efficient machining .

❖ Reducing the bubble formation near the tool.

❖ Achieving the accurate dimensions of hole.

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Literature review
Sr.no Title Author Year Conclusion
1 Electrochemical micromachining Kees De Regt 2022 • ECM offers advantages over
traditional machining
c. van Osenbruggen methods, including rapid
metal removal, absence of tool
wear, no burr formation, and
the ability to produce complex
shapes without introducing
mechanical loads or
deformations.
• Compared to methods like
electro-discharge machining
(EDM), ECM's benefits
include rapid metal removal
and minimal tool wear, though
it requires complex equipment
and empirical adjustments.

8
Literature review
Sr.no Title Author Year Conclusion
2 Electrochemical micromachining: Rebecca J Leese 2023 This article discusses the
An response of ECM to the trend of
introduction Atanas Ivanov miniaturization, emphasizing
recent developments such as
pulsed electrochemical
machining (PECM), which utilizes
high-frequency voltage pulses to
confine machining to specific
areas of the workpiece. PECM
offers enhanced resolution and
allows for the reduction of the
inter-electrode gap (IEG),
contributing to improved
machining accuracy.

9
Literature review
Sr.no Title Author Year Conclusion
3 A review on process capabilities Krishna Kumar 2023 This comprehensive review
of electrochemical Saxena systematically explores the process
micromachining and its capabilities and research
advancements of electrochemical
hybrid variants
micromachining and its hybrid
variants, drawing from a wide
spectrum of multidisciplinary
knowledge in both basic and applied
research fields. By bridging the gap in
research literature, this review
presents an extensive compilation of
recent developments in
electrochemical micromachining
technology and its hybrids, offering
insights into technological
understanding crucial for future
engineering developments in this
domain.

10
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Parameters affecting

1. Electrolyte Composition
2. Tool Design and Material
3. Workpiece Material
4. Gap Distance
5. Electrolyte Flow Rate

13
Static vs dynamic electrolyte
Static Electrolyte System:
◦ Advantages: Simplicity, uniform distribution.
◦ Limitations: Limited electrolyte movement during machining cause more temperature rise

Dynamic Electrolyte System:

◦ Continuously circulating electrolyte over workpiece and tool.
◦ Advantages: Enhanced flushing, Temperature control.
◦ Limitations: Increased complexity, higher costs.

14
 Red wood viscometer experiment
Temperature(°C) Time (sec) Viscosity (cm²/s)

23 45.76 0.0932

33 39.59 0.0732

43 34.47 0.0553

53 30.45 0.0405

63 26.98 0.0265

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Red wood viscometer experiment

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Calculations for Output flow
Area = (π*D^2)/4
= π*0.6^2/4
= 0.2827cm^2

Velocity (V)= √(2gH)

= √(2*9.81*5)
= 9.90cm/sec

Volume flow = A* V
= 0.2827*9.90
= 2.8 cm^2/sec = 2.8 ml/sec

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Calculations for velocity of electrolyte
Feed = 0.007mm/min
Voltage =8V
Diameter of tool =0.015cm
Boiling Point =198°C
Viscosity = 0.09329 cm²/s
Density = 1.175 g/ml
Ambient temperature = 23°C
Specific heat = 2.218 J/g°C
Conductivity (K) =1/1.21*(10**6) Ω-1cm-1
Faradays constant(C) =96500

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Calculations for velocity
Dynamic viscosity = Kinematic viscosity * Density
= 0.09329*10^(-4)*1175
= 0.0109 Kg/m-s

The equilibrium gap(Ye) = ((8*10^6)*55.85*6.5)*60/(1.175*2*96500*0.0007

= 1.13cm

Current density (J) = K*v/Ye

= ((8*10^6)*6.5)/1.13
= 0.4737 amp/cm^2

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Calculations for velocity
Velocity =((J^2)*L)/K *theta*density*C
= ((0.4737^2)*0.015)/((8*10^6)*150*1.175*2.218
= 10.42 cm/sec

Diameter of nozzle = 0.5 cm

Flow Rate = Area * Velocity

= (9.81*0.25^2)*10
= 1.963 cm3/sec = 1.963ml/s

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Tank Design

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Simulation

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Pump Selection

Condition :

Distance: 1meter

Flow rate: 2.5-6 ml sec

Specification:

Operating voltage : 3-6 V

Operating current : 130-220 mA

Flow rate: 80 L/Hr

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Pump Selection
Condition :

Distance: 1meter

Flow rate: 2.5-6 ml sec

Specification:

Operating voltage : 12 V

Operating current : 330 mA

Flow rate: 120 L/Hr

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Filter selection
Condition :

Flow rate: 2.5-6 ml sec

Specification:

Filtration capacity : 100 liter

Filter size: : 1 micron

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Assembly

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Costing
Component Specification Cost
Dimensions:
Length:150mm
Tank Width:150mm ₹400
Height: 75 mm

Pipe Transparent pipe ₹20

Length :400mm
Filter Filtering range: 1-2 micron ₹100

Valve Input diameter: ₹50

Output diameter:

Flexible pipe Length : 400 mm ₹150

Diameter: 10mm
Pump 12volt ₹500

Adaptor 12volt ₹150

PRESENTATION TITLE 27
.
Advantage of electrochemical machining

• High Precision

• No Mechanical Contact:

• Suitable for Heat-Sensitive Materials:

• Burr-Free Machining:

• Complex Geometries:

28
Result
Tank output 2ml/sec

Tank input 1.5ml/sec to 10 ml/sec

Filtration capacity 1 micron

Result Optimized Flow- A

specific flow rate of electrolyte resulted in improved machining performance.
Velocity Effects: Higher velocity were
found to facilitate better material removal rates
Effect of Filtration: filtration system in the electrolyte flow path
was found to be beneficial in maintaining a clean and consistent electrolyte supply

PRESENTATION TITLE 29
 ECMM applications

Microelectromechanical systems Microelectronic components

Precision optics and lenses

1.Micro-molds for micro-injection molding Microfluidic devices

30
References
1] E. Uhlmann, B. Mullany, D. Biermann, K.P. Rajurkar, T. Hausotte, E. Brinksmeier,
Process chains for high-precision components with micro-scale features, CIRP
Ann. - Manuf. Technol. 65 (2) (2016) 549–572.

2] R. Schuster, V. Kirchner, P. Allongue, G. Ertl, Electrochemical micromachining,

Science (80-. ) 289 (5476) (2000) 98–101.

3] A review on process capabilities of electrochemical micromachining and its

hybrid variants (Krishna Kumar Saxena)

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References
4] "Electrochemical Micromachining Using a Pulsating Jet Electrolyte Flow" by Y.C. Shin, J.M. Kim,
J.Y. Park, and S.G. Lee. Published in the International Journal of Advanced Manufacturing
Technology in 2013. This paper discusses the use of a pulsating jet electrolyte flow in ECMM
processes.

5] "Electrochemical Micro Machining with Pulsating Jet Electrolyte Flow" by K. Rajurkar, M.

Kozak, and M. Guo. Published in the Annals of the CIRP in 2006. This paper explores the application
of pulsating jet electrolyte flow in micro machining and its effects on process performance.

6] "Investigation of Flow-Field in Electrochemical Micro-Machining with Pulsating Jet Electrolyte

Flow" by Y.C. Shin, J.M. Kim, and S.G. Lee. Published in the Journal of Advanced Mechanical
Design, Systems, and Manufacturing in 2013. This study delves into the flow-field characteristics in
ECMM processes utilizing pulsating jet electrolyte flow.

7] "Electrochemical Micromachining with Reciprocating Electrolyte Flow" by T. Masuzawa, H.

Aoyama, and T. Nakagawa. Published in the CIRP Annals - Manufacturing Technology in 2008. The
paper discusses ECMM with reciprocating electrolyte flow and its influence on machining
performance.
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 Time Activity Chart
Sr. No Activity January February March April
1 Problem definition

2 Literature Survey

3 Numerical analysis

4 Experimental study

5 Report Writing

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 Thank you

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