Experimental setup development and parametric study of electrochemical face grinding process using Ni-based superalloy

Electrochemical grinding (ECG) process is an advanced machining process in which electrochemical action is used to remove the material from the workpiece atom by atom. Mechanism of metal removal in ECG is same as in case of ECM. In ECG, tool is used in the form of disc and rotating at certain rpm while in ECM, the solid sinking tool is used. Electrochemical face grinding (ECFG) process is one of the variants of ECG process in which axis of tool (disc shape) is perpendicular to the workpiece surface and material is removed due to electrochemical action between face of the wheel and workpiece surface. This process can be used for machining flat surfaces which are difficult to machine by conventional machining processes. In this study, a new set up of ECFG process is developed and then experimental study has been done using one-parameter-at-a-time (OPAT) approach. The experimental results suggest that both response parameters, surface roughness (Ra) and material removal rate (MRR) increases with elevated values of electrolyte concentration, feed rate and voltage. MRR also increases with wheel speed while Ra decreases with wheel speed.