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ISSN 2063-5346
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A novel approach to electrochemical machining etching using solar energy at a low cost for steel, stainless steel, and aluminum sheets with different electrolyte concentrations

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G.A.El-Awadi*,
» doi: 10.48047/ecb/2023.12.10.759

Abstract

Recent studies have successfully decreased the expenses associated with machining processes. The utilization of solar energy in the electrochemical etching process has the potential to offer a sustainable and economically viable solution. This study aims to investigate the impact of varying sodium chloride (NaCl) electrolyte concentrations on material removal rate (MRR) in machining. To conduct this investigation, a solar energy setup will be utilized, which will involve the utilization of solar power generated by a panel or stored energy in a direct current (DC) battery. The DC power supply of the controller will be employed to convert the stored energy into alternating current (AC). By employing this setup, we will be able to examine the performance of machining under different NaCl electrolyte concentrations. The experimental data was collected from the solar panel at various time intervals, specifically at 11 a.m., 12:00 p.m., 1:00 p.m., 2:00 p.m., and 3:00 p.m. The machining process lasted for a duration of 60 minutes, while the concentration of the electrolyte used was 1 mole of NaCl. The distance between the two electrodes was set at 20 mm, and the angle of the solar panel was adjusted to 17 degrees. The substrate materials utilized in this study included aluminum, steel, and stainless steel, all of which were machined to possess identical dimensions as the anode and cathode, measuring 20x20x2 cm. The results have been presented, revealing the experimental observations that indicate the highest recorded values of current and voltage occurring at 12:00 PM. The maximum removal rate (MRR) is observed for aluminum, steel, and stainless-steel materials at 12:00 PM. The impact of varying electrolyte concentrations (0.5, 1, 1.5, and 2 moles/liter) on the material removal rate (MRR) is examined. The MRR values for aluminum, steel, and stainless steel at 2 moles/liter are found to be 0.05166, 0.0234, and 0.0195 gm/min, respectively, indicating the highest rates of material removal.

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