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Journal of Electrochemical Science and Engineering, Vol. 15 No. 6, 2025.

Original scientific paper

https://doi.org/10.5599/jese.2821

Electrochemical micromachining of galvanized iron sheets: process optimization and performance evaluation

Nadanasabapathi Sivashankar ; Department of Mechanical Engineering, Kongunadu College of Engineering and Technology (Autonomous), Trichy, Tamilnadu, India *
Kadhiresan Santhanam ; K. S. Rangasamy College of Technology, Tiruchengode, Namakkal, Tamil Nadu 637215, India
Shikandar Prasad orcid id orcid.org/0009-0000-4468-3083 ; Government Engineering College, Nawada, Bihar 805110, India
Mamidala Jawahar ; Jayamukhi Institute of Technological Sciences, Narsampet, Warangal, Telangana 506332, India
Rajasekaran Thanigaivelan orcid id orcid.org/0000-0001-9514-9120 ; Department of Mechanical Engineering, Shreenivasa Engineering College, Dharmapuri, Tamilnadu, India

* Corresponding author.

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Abstract

Electrochemical micromachining (ECMM) is a promising non-traditional technique for fabricating micro-features on conductive materials with high precision and minimal thermal effects. This study focuses on the ECMM of galvanized iron (GI) sheets using sodium nitrate (NaNO3) as the electrolyte. Key process parameters such as voltage, duty cycle, and electrolyte concentration were optimized to improve machining performance in terms of material removal rate (MRR) and overcut (OC). An L9 orthogonal array was used to design the experiments, and signal-to-noise ratio, along with analysis of variance (ANOVA), was employed to identify the most influential parameters. Results showed that voltage signi­ficantly influenced both MRR and OC, with optimal MRR observed at 12 V, 70 % duty cycle, and 20 g l-1 NaNO3 concentration. Conversely, the minimum OC was achieved at 6 V, 50 % duty cycle and 10 g l-1 NaNO3 electrolyte concentration. SEM analysis confirmed over-etched boundaries at higher voltage and well-defined micro-holes at lower voltage. This research demonstrates the critical role of parameter tuning in enhancing the quality and precision of ECMM on GI sheets.

Keywords

Galvanized steel; electrochemical material removal; machining parameters; removal rate; overcut

Hrčak ID:

339945

URI

https://hrcak.srce.hr/339945

Publication date:

31.7.2025.

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