ASSIGNMENT 8

1. The composition (% by weight) of nomonic 75 alloy is given in the accompanying table: Element % by weight Atomic Weight Valency Density
i)

Ni 72

Cr 20

Fe 5

Ti 0.5

Si 1 28.09 4 2.33

Mn 1 54.94 2,4,6,7 7.43

Cu 0.5 63.5 1,2 8.96

58.71 51.99 55.85 47.90 2,3 8.9 2,3,4 7.19 2,3 7.89 3,4 4.51

Calculate MRR (specific MRR and volumetric MRR) when a current of 2000 A is used. Use the lowest valency of dissolution in each case. Determine the equilibrium gap if applied voltage = 15V, Over potential =1.5 V , specific resistance = 0.21 ohm cm and feed is 1mm/min Calculate the rise in temperature for the following machining conditions: feed rate =0.05 mm/s, room temperature =38 deg, electrolyte density = 1.05 g/cm3 , efficiency = 100 %. Electrolyte flow rate = 120 LPM. Flow velocity = 2000 cm/s and specific heat = 1.06 cal/g C. Geometry of the work piece surface with single curvature is given by the following equation y = 10 x0.20x -0.05 x2, where x and y are in centimeters. The following details are as follows: Applied voltage =15 V. Over potential =0.67 V, feed rate = 0.75 mm/min, work material = copper (atomic weight = 63.57 and valency = 1) density = 8.96 g/cm3 . specific resistance = 0.2 ohm cm

ii)

iii)

iv)

6. Show that in a constant current ECM drilling process, the hole size decreases inversely as a function of square root of feed rate.

7. Prove mathematically that, in a constant feed rate ECM system, the machining process is inherently self regulated since the MRR tend to approach the feed rate. 8. What is Joule heating as applied to ECM; derive an expression for the flow rate of electrolyte to prevent boiling and velocity of the electrolyte flow.

Practice problems
1. In a ECM process, for machining of iron, a metal removal rate of 1cm3 /min is desired. Determine the necessary current; assume atomic weight of iron to be 56. Its valency 2 and density 7.8 gm/cm3. Faradays constant may be taken as 96540 coulombs. 2. Estimate the MRR of an alloy containing 18% cobalt, 62% nickel, 20% chromium, during electro chemical machining with a current of 500 amperes. The density of the alloy is 8.28 gm/cc. The following data is available.

Metal Gram Atomic Weight Cobalt 58.63 Nickel 58.71 Chromium 51.99 Faradays constant = 96500 coulombs /mole

Valency 2 2 6

3.A dc power supply of 18 Volts and 5000 A was used in ECM using copper electrode and sodium chloride solution. A tool work gap of 0.5 cm was maintained. The data for Iron anode may be taken as: Atomic weight = 56, valency = 2, density = 7.87 g/cm3. Calculate the machining rate and electrode feed rate for the following data for the electrolyte

4. An ECM with copper electrode and NaCl as electrolyte is used for machining of iron. The ECM has the following dimensions: Electrode area = 2.54 x2.54 cm, Electrode work gap=0.0254 cm. The electrolyte properties are : specific heat= 4.17 J/g-k, Density= 1g/cm3, specific resistance = 3 ohm cm. Estimate the permissible fluid flow velocity, if the maximum permissible temperature of electrolyte is 95 deg and ambient temperature is 30 deg. Applied voltage is 12 V. Calculate the maximum MRR if the current density is 160 cm/cm2