Experimental Investigation and Modelling Studies on MHD Convection in Magnetic-assisted -ECDM

The present work concerns microchannel fabrication using magnetic-assisted electrochemical discharge machining on silica glass. The magnetic field regulates the process by controlling bubble formation and separation adjacent to the tool edge. Due to the applied magnetic and electric flux on the electrolyte and electrode interface, the Lorentz force impacts the bubble establishment and film quality. The fractional bubble coverage decreases with the magnetic field, which increases the current density and affects the discharge frequency. The analytical model is explored here to investigate the magnetic field influences on departure radius. A novel approach has been adopted to couple the Laplace and Navier stokes equations for studying the magnetohydrodynamic effect. The experimental and analytical results reveal that magnetic flux decreases the bubble departure radius. The regression model explains the impact of controllable factors on surface roughness, material removal rate, and width overcut. The multi-response optimization with the hybridization of response surface methodology and grey relation analysis technique provides the optimum value of material removal rate, width overcut and surface roughness as 1.2 mg/min, 0.046 mm, and 1.58 µm, respectively.