Project: Optimization of ECM Machining Parameters on Hastelloy C22

This project focuses on optimizing the machining parameters of Electrochemical Micro Machining (ECM) for Hastelloy C22, a nickel-based alloy known for its corrosion resistance. The student utilized the Taguchi-Grey relational analysis method to enhance the efficiency of the manufacturing process. The project involved experimental setups, parameter optimization, and analysis of factors such as applied voltage, electrolyte concentration, duty cycle, and current. The objectives included optimizing machining parameters, applying Taguchi-Grey methodology, ensuring optimal results, and analyzing the impact of process parameters on machining performance, material removal rate, and surface finish. The student's role included identifying project topics, selecting appropriate methods, conducting research, and documenting findings, including addressing technical challenges and collaborating with team members. The report details the experimental setup, methodology, the identified technical issue (current range), and the solutions applied. The project's goal was to provide maximum advantages and better applications by identifying the optimal mixture of process parameters to gain better response values and to find out the most inducing input process parameter within electrochemical micro machining.

CE 1.1 Information of Project
Name of the Project: Optimization of Machining Parameters on Electrochemical
Micro Machining of Hastelloy C22 using Taguchi-Grey Relational Analysis
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Team Member of the project
CE 1.2 Background of this Project work
CE 1.2.1 Basic Characteristics of the Project
ECM or electro chemical machining is one of the most common terms for several
distinct electro chemical processes and is often referred to as one of the most recent
technologies. The electrolysis method is being utilized for removing the metal from the work
piece and it is best suited for different machines and alloys that are much difficult to be
properly machined by process of mechanical machining. In this project work, I had to
optimize the machining parameters over the electro chemical micro machining of Hastelloy
C22 with the help of Taguchi Grey relational analysis. Hastelloy C22 is a specific nickel
based and corrosion resistant face centric cubic nickel, molybdenum and chromium alloy. I
had to complete the experimental set up with different components. I selected Taguchi
method, since it is the most effective method for improving the overall quality of the
manufactured goods that is being applied to different mechanical engineering projects to
bring out innovation. Hence, I had efficaciously executed this project of optimization of

different machining parameter over the electro chemical micro-machining of Hastelly C22
with the help of Taguchi method.
CE 1.2.2 Developed Objectives for the project work
While executing the project of Optimization of Machining Parameters on
Electrochemical Micro Machining of Hastelloy C22 using Taguchi-Grey Relational Analysis,
I had to ensure that I am able to contribute to the efficiency of the respective production
process and even reducing the expenses of this experiment to a greater extent. Therefore the
objectives of this project:
 To optimize the machining parameters over electro chemical micro machining of
Hastelloy C22.
 To use the popular methodology of Taguchi Grey for relational analysis.
 To ensure that the machining parameters are well optimized and proper results are
being gained without much complexity.
 To make sure that the disadvantages of electro chemical process are not affecting the
overall effectiveness of the project work.
 To ensure that the project work is providing maximum advantages and better
applications to the users.
 To complete an analysis on the overall impact of each process parameter over the
machine performances on Hastelloy C22.
 To identify the optimal mixture of process parameter to gain better response values.
 To find out the most inducing input process parameter within electrochemical micro
machining.
 To ensure whether the respective project outcome is eventually matching with my
predictable outcomes or not.

CE 1.2.3 My working area in this project
I was one of the most responsible team members in the project work of Hastelloy
C22. Since, I was a student, my project supervisor selected three of us for assisting him in
this project. We were well guided by him and the project became a success. The idea to
execute this project was mine and I discussed with my other team members to take their ideas
and concepts about the topic. With my basic knowledge of Taguchi method and electro
chemical process, I made sure that each and every project duty, given to me is eventually
completed. Furthermore, I also tried in helping out my classmates or other team members for
providing them with guidance.
CE 1.2.4 Group of people Involved in Project
Figure 1: Team Members of this Project Work
CE 1.2.5 My main responsibilities and duties throughout the work
For completing this project of Hastelloy C22, I comprised of a couple of
responsibilities. Being a final year student, my first and foremost responsibility was to
provide a suitable and appropriate topic for the project, only after researching properly.
Researching was required as it helped me in clearing out my doubts and hence I was able to

complete this project work efficiently and without any type of difficulty. I identified the
problem for which I had to search for solutions. The first problem that I had identified was
that Hastelloy C22 comprises of high corrosion and no machine has ever been machined and
analysed electro chemically for this purpose. The second issue that I had identified and from
where I got the idea of executing this project was that as the alloy finds its utilization in the
micro heat exchangers, MRR and surface finish are the most significant parameters, which
are needed to be improved. After identifying the issues and selecting a proper project, my
next responsibility was to select an effective method that can easily execute the project work.
I selected Taguchi Grey method for this purpose. Documentation and preparing project
reports were the next significant duties within the project.
CE 1.3 Distinct Activities in this Work
CE 1.3.1 Comprehending the most Basic Theories Used in this Project work
I had to take up theoretical knowledge for the electro chemical machining process and
Hastelloy C22. I have understood that electro chemical machining is a specific contactless
machining process, where the entire procedure is not being subjected to tool wear,
mechanical stresses as well as micro-fissure. I ensured that I am well acquainted with the
entire concept of electro chemical machining process. I even understood that several factors
can influence the performance of micro machining such as inter electrode gap, machining
voltages, micro tool feed rate, concentration and type electrolyte and nature of power supply.
The respective principle of ECM process was being applied in this project work.

Figure 2: Schematic Diagram of Electro Chemical Machining Process
Moreover, I selected Hastelloy C22, since it comprises of different metals and alloys
and can be extremely effective for the project work. I have used Taguchi Grey methodology
after using several input parameters of material removal rate, surface finish and over cut. I
was hence successful in finding out an optimum set of results for the project after analysis.
CE 1.3.2 My main Engineering skills or knowledge that are applied in the work
To complete this particular project work, I had to apply my skills and knowledge
related to mechanical engineering. Being an expert in different sectors of metallurgy, it was
extremely easy for me for completing the entire work without much complication. I have
applied my intense knowledge of metal casting, mechanical metallurgy and mineral
processing for successfully optimizing the machining parameters in this project work.

Moreover, I have even used my intense knowledge of Tagushi Grey for completing relational
analysis of Hastelloy C22.
CE 1.3.3 Execution of the work and main Tasks Completed in this work
I had utilized the different components of micro ECMM, pulse rectifier, tool holder,
electrolyte bath, flow control, servo motor and filter and pump for completing the
experimental set up. I conducted the machining process trial experiments for determining the
total range of input parameters such as applied voltage, electrolyte concentration, duty cycle
and current, which could be pre-set before actual experiment. For better analysis and
accessibility, the respective output parameter surface was drilled and a blind hole was made. I
took up the Hastelloy C22 composition as follows:
Table 1: Composition of Hastelloy C22
I selected Taguchi method for better optimization of the process variables and the
method eventually provided with expected information or data from lowest numbers of trial
with each level. The design of experiments is as follows:

Table 2: Design of Experiments
CE 1.3.4 Identified issue with its solution
1.3.4.1 Issue in this project
The extremely noteworthy technical issue, which I had to confront here was while
specifying the electro chemical machining process. In the beginning, I had undertaken up the
subsequent range of current between the ranges of 10 to 40A, which was quite higher for the
project. I did not get accurate results and this particular project was eventually delayed.
1.3.4.2 Accurate Solution to the identified Technical Difficulty
To solve the specific technical issue of specification, I eventually provided the idea of
reducing the current range. I selected the range of 0.10 to 30A and was finally able to set up
the experiment successfully.

Table 3: Specification of ECMM
CE 1.3.5 Major Plan made to provide innovative and even creative works
I had to make the most feasible and accurate planning to complete the different
mechanism of this project work. I even did proper research for learning about the concepts of
ECMM and Hastelloy C22. I also took help from the project leader and all other members of
team to provide the most accurate results.
CE 1.3.6 Work Collaborations
I submitted regular progress report and updates to my project supervisor and head of
the department while completing the project work. I even decided to organize team meetings
on weekly basis, so that we are able to identify our weaknesses and was able to solve them
successfully.

CE 1.4 Overall Reviewing of the Project
CE 1.4.1 Overview of this Project
I had to optimize the machining input parameters on electro chemical micro
machining of Hastelloy C22 with the help of Taguchi Grey relational analysis. Taguchi was
selected as the optimization method as it is a single response optimization technique. I was
able to achieve proper results in this process.
CE 1.4.2 My Major Contribution to this work
I comprised of few contributions in this project work. I had to research properly
regarding ECMM and Hastelloy C22 for understanding the entire concept effectively. I also
took regular updates and resolved the technical difficulty.