Study of mixed nanopowder into electrochemical machining process

Abstract

Electrochemical machining (ECM) is considered as most favored machining processes to produce many press tools and dies because of its good capability to manufacture complicated different shapes and machinability of very brittle and hard materials. This method has enabled the machining of all electrical conducting materials. In this research, the material of the electrode tool is made of copper, and it makes an impermeable cavity in the workpiece. The technique of nano graphite powder mixed could be more advanced to improve the capabilities of traditional ECM. The goal of this research is to enhance performance and quality of ECM process including enhancement of material removal rate (MRR) by discuss the results of using many input parameters like nano graphite powder concentration with values of (0, 5, and 10 g/L), voltage with values of (10, 20, and 30 V), and gap with values of (0.1, 0.2, and 0.3 mm) for machining stainless steel 304 ASTM A 240 on MRR. Minitab statistical software is utilized to analyze results statistically by general full factorial design to know how selected input parameters affect MRR. It is concluded that adding nano graphite powder with a mixture of water and sodium chloride (NaCl) increases MRR. Maximum MRR is (36.892 mm3/min) acquired at a nano graphite powder concentration of (10 g/L), a voltage of (30 V), and a gap of (0.3 mm). when nano graphite powder concentration, voltage, and the gap increase, MRR increases.