Influence of nanoparticles-suspended electrolyte on machinability of stainless steel 430 using electrochemical micro-machining process

In this present work, the experimental studies have been carried out on the electrochemical micro-machining (ECMM) process of stainless steel 430 by varying the process parameters such as electrolyte concentration, applied voltage, micro-tool feed rate and duty cycle. Microscopic image and SEM analysis have been characterised in the ECMM process. Therefore, the micro-level hole has been produced in the stainless steel 430 for the applications of fuel injectors and medical equipments. The detailed study on the influence of nanoparticles-suspended electrolyte analyses the response measurements such as material removal rate, overcut, circularity and cylindricity. Of the two machining conditions, the copper nanoparticles-suspended electrolyte enhances the performance measures of the machining surface, increases localisation region and reduces the stray current effect, while obtaining a uniform circularity profile, higher material removal rate and lesser overcut due to its high electrical and thermal conductivity compared to the without nanoparticles suspended in the electrolyte. The experimental results indicate the influence of variations in the electrolyte concentration, and the duty cycle has been most significant parameters in the cutting condition for copper nanoparticlessuspended electrolyte by ECMM process.