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The present work is focused on estimating the optimal machining parameters required for photochemical machining (PCM) of an Inconel 718 and effects of these parameters on surface topology. An experimental analysis was carried out to identify optimal values of parameters using ferric chloride (FeCl 3 ) as an etchant. The parameters considered in thi...
Citations
... Likewise, Rahul et al. [22] machined different grades of nickel alloy through EDM to explore the effect of process parameters over the surface roughness and tool wear rate. In another consulted research work of Misal et al. [23], surface roughness analysis of Inconel 718 has been carried out to understand the effect of photochemical machining parameters. Due to the difficulty in machining of Inconel 718, deep hole drilling has been realized through electric discharge drilling by Machno [24]. ...
Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.
... One of the easiest ways of fabrication is the Photo Chemical Machining process. The fabrication aspect of microchannels and suitable processes have been reported by different researchers [4][5][6][7][8]. Various fabrication methods like Micro Cutting, (Wet and Dry) Etching, Lithography, embossing and molding are used for the fabrication of microchannels. ...
Microchannels are widely used in many applications like micro fluidic, medical, biological and industrial applications. Microchannels are those channels having dimensions, less than one mm and greater than one micron. There are many methods to fabricate the microchannels, and it depends on the material on which microchannels are to be fabricated and the fabrication process used. There are many traditional and nontraditional methods for the fabrication of different microchannels. There are many materials which are used to manufacture the microchannels like glass, silicon, polymer, copper, aluminum, brass, etc. In this study, the copper microchannels are fabricated, having different shapes of obstacles by the photochemical machining process. Configuration of the obstacles, affect the microchannels performance. Based on this study, we conclude that the photochemical machining is one of the simplest and low-cost fabrication processes for the fabrication of microchannels.
... Various studies have been reported on the depth analysis, parametric analysis, edge deviation analysis for photochemical machining. The photochemical machining has already been used by various researchers for fabrication of microchannel molds, heat sinks, grooving in hydrodynamic journal bearing, etc. [7][8][9][10][11][12][13][14][15][16][17]. No significant study has been observed on 3D PCM. ...
... Various studies have been reported on the depth analysis, parametric analysis, edge deviation analysis for photochemical machining. The photochemical machining has already been used by various researchers for fabrication of microchannel molds, heat sinks, grooving in hydrodynamic journal bearing, etc. [7][8][9][10][11][12][13][14][15][16][17]. No significant study has been observed on 3D PCM. ...
Photochemical machining is an engineering production technique for the manufacturing of burr free and stress-free components in various industries. The thin, precision parts and complex geometries can be produced by using non-conventional machining process in diverse industries as aerospace, electronics automotive manufacturing. This paper focuses on study of three-dimensional photochemical machining at varying temperatures by using coloured photo tool. The process is starting with by designing of photo tool for different surface curvature. Cooper material was selected for experimentation, it has good electric and thermal conductivity. The control parameters selected were temperature, concentration and time. The temperature and time are varying parameter for etching. The depth of etch was measured by using Digital Micrometre having least count 0.001mm. The objective of this study is to achieve variable depth on two dimensional surfaces.3D PCM was carried out for flat surfaces followed by curved objects on copper.
... The analysis for effect of control parameters on the performance parameters like material removal rate, undercut, surface roughness has been reported by researchers for the copper and its alloys like brass, german silver, etc. [3][4][5][6]. The photochemical machining study for the hard to cut materials like Inconel has been also reported [7][8]. ...
... The effect of process parameters like concentration, temperature and etching time on the performances measures like material removal rate (MRR), the surface roughness (Ra), edge deviation (ED), etc. has been reported [3], [4], [5], [6]. The parametric optimization for PCM of different hard to cut materials like Inconel alloys have been carried out by researchers [7], [8], [9]. The PCM has also been employed for fabrication of micro features, micro channels [10], [11], [12] and can be used for micro features in hydrodynamic journal bearing [13]. ...
Generally mechanism consists of links, joints, pairs, etc. and the force and power are transmitted by the relative motion of these parts of the mechanism. Due to the relative motion of joints, the friction occurs which leads to a deficiency in the force and power transmission. A compliant mechanism is a monolithic and joint less structure. So, it eliminates the problem of friction in the mechanism. The accurate transfer of force and power is significant while handling small size objects, sensors, assembly parts, etc. This paper is based on the development and fabrication of compliant mechanism by photo chemical machining (PCM) and their characterization. Initially, we drafted the drawing of compliant mechanism and created the photo tool of the same. Copper material was selected for the manufacturing of the mechanism. The required photo tools were generated on trace paper, and then the micro gripper was fabricated using photo chemical machining. Further, the characterization of fabricated micro grippers was performed using RAPID I Vision 5 Microscope. The error analysis of fabricated micro grippers was performed with respect to the photo tool dimensions, and the error is observed to be minimum. So, it is concluded that the micro grippers can be fabricated using PCM up to satisfactory level.
... [7] and Atul R Saraf [8] has studied Parametric Optimization for Photochemical Machining of Copperusing Overall Evaluation Criteria and obtained results by Taguchi's approach. Various studies have reported the parametric optimization of photochemical machining and fabricated the microchannels using photochemical machining [9][10][11][12][13][14]. II.METHODOLOGY ...
... Saraf and Sadaiah [7] used a magnetic field as an influential factor to increase the etch rate. Misal and Sadaiah [8] investigated the effects of process parameters in PCM on the surface roughness in PCM of Inconel 718. Kunar and Bhattacharyya [9] reported that chemical etching capable as micromachining technique to fabricate different surface textures. ...
This investigation is focused on the surface integrity of Co-Cr L605 using photochemical machining (PCM). The study focuses mainly on the effects of different manufacturing processes, such as forging, wire-EDM, and rolling, on the metallurgical parameters of Co-Cr L605 in PCM. Results were obtained for residual stresses, grain size, local grain misorientation, and interplanar distances. Effects on the etch rate and surface roughness were studied, and found to be maximum for forging, while they were lower for rolling. An overall study was conducted to correlate PCM process parameters with bio-functional aspects of the Co-Cr L605 alloy.
... PCM industry plays a valuable role worldwide in the production of precision parts and decorative items. PCM is also known as photo etching, photochemical milling, photo milling, photo fabrication, photochemical etching and chemical blanking [4][5][6][7][8][9]. ...
... Patil et. al. has studied in the metallurgy in the perspective of PCM [5,7].The proposed work of PCM can play an important role in microcomponents manufacturing and reduces a cost of tooling [4][5][6][7][8][9][10]. ...
The paper presents the design, analysis, and manufacturing of bare metal coronary stent using Photochemical Machining (PCM). Stent is used to overcome the coronary Heart diseases (CHD) by inflating the narrowed of arteries. The finite element analysis has been carried out to investigate critical region and parameters in the perspective of efficient mechanical performance for designed stent. The numerical simulation of crimping process and balloon expanding has been carried out. The crimping is done up to 2 mm mean diameter with external pressure of 0.42 MPa. And again by applying internal pressure of about 1.2 MPa expand stent up to original dimension of 4 mm. The Photochemical Machining is new approach of has been characteristically employed in manufacturing of stent. In this work 3D micro image printing incorporated with UV light curing for production of required pattern. The aim of this work is to manufacture designed shaped bare metal stent prototype with minimum surface roughness. Wet chemical etching process is used for manufacturing a stent from the optimized etching parameters. Input parameters are concentration of etchant 500 g/l, time of etching 50 minutes and etching temperature is 50°C.
Photochemical Machining (PCM) is a well-known tightly controlled selective corrosion technique used to manufacture several micro and nano-size components high in quality and high precision; as it is a non-contact process, it gives a burr-free stress-free surface of the material. Nowadays, PCM is widely used in various industrial applications, including medical and healthcare industries, electronics, precision micro, nano, and other engineering industries. This article describes the correlation between various process parameters like etching temperature, time, and concentration of etchant with some response parameters like surface roughness value, metal removal rate (MRR), undercut (Uc), etch rate. In addition, magnetic field-assisted PCM and ultrasonic-assisted PCM are also explored in detail. The article highlights that etchant concentration and etching time play the most critical role in the PCM process. This article also depicts that with the increase in etchant temperature and etching time, the MRR and undercut increases. The article suggests future scopes and challenges of photochemical machining process.
