Table of Contents
Machining of electrically non-conductive alumina (Al2O3) ceramic is still a major problem. A hybrid machining technique known as electrochemical spark machining (ECSM) can be utilized to machine the electrically non-conductive ceramics. In the present study, micro electrochemical spark drilling (MESD) experiments have been conducted utilizing steel micro tool on designed and fabricated micro electrochemical spark machining (MESM) setup. Electrically non-conductive high-strength high-temperature-resistant Al2O3 ceramics selected as work-piece material. From the test results, it has been found that the machining voltage range from 85 to 90V, electrolyte concentration range from110 to 100g/l and gap between electrodes range from 100 to 110 mm gives higher material removal rate (MRR). Utilizing the test results mathematical models for MRR and micro hole depth are established for effective machining of Al2O3 ceramics. Different SEM graphs of the micro holes were taken to analyze the surface texture of the machined hole.
Keywords: Al2O3 ceramics; MESM; MRR, SEM graph