Mathematical Modelling and Optimization of Photochemical Machining

Abstract:

Photochemical Machining is a novel machining process capable of processing wide range of hard-to-machine materials. This research addresses modelling and optimization of the process parameters for this machining technique. To model the process a set of experimental data has been used to evaluate the effects of various parameter settings in machining of SS316L. The process variables considered here include etchant temperature, time and concentration. Undercut, as one of the most important output characteristics, has been evaluated based on different parameter settings. The full factorial method and regression modelling are used in order to establish the relationships between input and output parameters. The effect of control parameters on undercut was analysed using Analysis of Variance (ANOVA) technique and their optimal conditions were evaluated. It was found that etchant temperature and etching time are the most significant factors for undercut.

• Periodical: Advanced Materials Research (Volume 548)
• Pages: 617-622
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.548.617
• Online since: July 2012
• Authors: Atul R. Saraf, Nitin D. Misal, M. Sadaiah
• Keywords: Mathematical Modeling, Optimization, Photochemical Machining, Regression Analysis, SS316L

References

[1] Atul R. Saraf, M. Sadaiah, Santosh Devkare, 2011. Optimization of photochemical machining, Int. Journal of Engineering Science and Technology, Vol. 3, No. 9, 7108-7116.

[2] Atul R. Saraf, M. Sadaiah, 2011. Photochemical Machining of SS304. Int. Journal of Advances in Science and Technology. Vol. 3, No. 6, 71-85.

[3] Allen, David M. Photochemical Machining: From Manufacturing's Best Kept secret to a $6 Billion per annum, Rapid Manufacturing Process, CIRP Journal of Manufacturing Systems, 53, 2005, 559-573.

DOI: 10.1016/s0007-8506(07)60029-8

[4] Cakir, O, 2008, Chemical etching of aluminum, journal of materials processing technology, 199, 337–3400.

[5] Cakir, O, 2006, Copper etching with cupric chloride and regeneration of waste etchant, journal of materials processing technology, 175, 63–68.

DOI: 10.1016/j.jmatprotec.2005.04.024

[6] Allen, David M., Almond, Heather J. A, 2004, Characterization of aqueous ferric chloride etchants used in industrial photochemical machining, Journal of Materials Processing Technology, 149, 238–245.

DOI: 10.1016/j.jmatprotec.2004.02.044

[7] Allen, David M., Talib, T.N., 1983, Manufacture of stainless steel edge filters: an application of electrolytic photopolishing, precision engineering, 57-59.

DOI: 10.1016/0141-6359(83)90028-4

[8] Allen, David M., Talib, T.N., 1983, "Surface textures and process characteristics of the electrolytic photoetching of annealed AlSl 304 stainless steel in hydrochloric acid precision engineering.

DOI: 10.1016/0141-6359(83)90027-2

[9] Davis, P.J., Overturf, G.E., 1986, Chemical machining as a precision material removal process, precision engineering , 67-71.

DOI: 10.1016/0141-6359(86)90088-7

[10] Douglas, C. M., 1997, Design and Analysis of Experiments. Fifth Edition, John wiley and sons, INC.

[11] Jonathan, M., George, M. A., 1995, Direct printing of etch masks under computer control, Int. J. Mach. Tools Manufacture. Vol. 35, No. 2, 333-337.

DOI: 10.1016/0890-6955(94)p2391-r

[12] Roy, R, Allen, D.M. and Zamora, O Cost of photochemical machining, Journal of Materials Processing Technology, 149, 2004, 460–465.

DOI: 10.1016/j.jmatprotec.2004.01.059