Experimental investigation on the suitability of dual fluid system-assisted ECM (DF-ECM) and the influence of magnet in machining of SS304

In electrochemical machining, acids are extensively used as electrolytes to machine components. The use of acids to machine SS304 pollutes the environment and has a lot of safety issues. Hence, the use of environmentally friendly electrolytes is in high demand. NaCl is an eco-friendly electrolyte and is abundantly available at a lower price. The aim of this research is to propose a method to effectively use NaCl electrolyte to machine SS304. In this research, a novel method of machining using a dual fluid system has been adopted to machine SS304. A dual fluid system uses two fluids during the machining process. The anodic dissolution of the workpiece is done by the primary fluid system that uses NaCl, while the secondary system is used to supply fluids that prevent the removal of material from unwanted regions in the machining zone and also aid in the removal of by-products formed in the machining zone. The purpose of the secondary fluid system is to act as a resistance towards the removal of material from unwanted regions. In all the experimental conditions, NaCl was used as fluid in the primary fluid system. In the secondary fluid system, aqueous solution of NaCl, NaNO 3 , NaHCO 3 , C 12 H 22 O 11 , and distilled water was used. Moreover, the influence of magnet is also studied. It was observed that when machining was done under the influence of a magnet, a reduction of stray current intensity was observed when using NaCl in secondary fluid system, thereby contributing to less severe attach in the workpiece. The output responses were evaluated based on taper angle, radial overcut, MRR, surface roughness, and radial-stray current affected zone. The combination of the primary and secondary fluid systems in dual fluid system-assisted ECM (DF-ECM) is an advanced electrochemical machining (ECM) process, which offers several advantages, including better control over the machining process, improved surface finish, and reduced chances of pit formation at the entry side of the hole.