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<p>This study explores the use of mixed electrolyte of Citric acid (lemon solution)-NaCl as an eco-friendly alternative for Ultrasonic Assisted Rotary Electrochemical Discharge Machining (UA-RECDM) of borosilicate glass. Experiments were performed by varying citric acid concentration in the range of 10–50% wt./vol while other parameters including voltage (40&#xa0;V), pulse on–off time (2&#xa0;ms–2&#xa0;ms), NaCl concentration (5% wt./vol.), tool feed rate (0.8&#xa0;mm/min), tool vibration amplitude (6&#xa0;µm) and workpiece rotation (60 RPM) remains constant. Hole overcut (HOC), Heat Affected Zones (HAZ), Fume Mass Concentration (FMC), morphology of fume particles and chemical composition were observed as performance characteristics. An increase in citric acid concentration from 10 to 50% wt./vol. led to a rise in HOC from 78.47&#xa0;µm to 322.45&#xa0;µm and decrease in HAZ area from 0.367 mm<sup>2</sup> to 0.205 mm<sup>2</sup>. Machined holes exhibits circular geometry with smooth edges indicating better surface quality at optimum electrolyte concentration of 30%. FMC increases from 11.4 3&#xa0;mg/m<sup>3</sup> to 81.96&#xa0;mg/m<sup>3</sup> with increment in citric acid concentration from 10 to 50% wt./vol. due to acceleration in electrochemical reactions &amp; higher discharge energy. FMC is 453.8% higher at 50% citric acid concentration in comparison to lower concentration of 10% indicates direct relationship between electrolyte concentration and fume production. Fume particles exhibits spherical, irregular and agglomerated morphologies with sizes in the range of 1 to 13&#xa0;µm. Chemical composition analysis of fume particles reveals the presence of oxidized, organic, metallic particles, nitrogen dioxide (NO₂), methane (CH₄) and aromatic compounds. The use of a mixed Citric acid-NaCl electrolyte effectively prevents the formation of hazardous components such as sulphur compounds, titanium (Ti), chromium (Cr) and halogenated substances. These findings highlight the potential of citric acid based electrolyte as a sustainable and safer solution for precision glass machining with minimal impact on environment and operator’s health.</p>

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Process optimization and emission analysis of sustainable UA-RECDM machining of borosilicate glass using Citric Acid-NaCl electrolyte

  • 期刊论文

  • 发表日期：

    2026年1月24日

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  • Sahil Grover,
  • Sarbjit Singh,
  • Sanjay Kumar Mangal,
  • Manpreet Singh,
  • Abhinav Kumar,
  • Lilia El Amraoui,
  • Kais Ouni,
  • Ankit Sharma,
  • Ankit Dilipkumar Oza

摘要

This study explores the use of mixed electrolyte of Citric acid (lemon solution)-NaCl as an eco-friendly alternative for Ultrasonic Assisted Rotary Electrochemical Discharge Machining (UA-RECDM) of borosilicate glass. Experiments were performed by varying citric acid concentration in the range of 10–50% wt./vol while other parameters including voltage (40 V), pulse on–off time (2 ms–2 ms), NaCl concentration (5% wt./vol.), tool feed rate (0.8 mm/min), tool vibration amplitude (6 µm) and workpiece rotation (60 RPM) remains constant. Hole overcut (HOC), Heat Affected Zones (HAZ), Fume Mass Concentration (FMC), morphology of fume particles and chemical composition were observed as performance characteristics. An increase in citric acid concentration from 10 to 50% wt./vol. led to a rise in HOC from 78.47 µm to 322.45 µm and decrease in HAZ area from 0.367 mm2 to 0.205 mm2. Machined holes exhibits circular geometry with smooth edges indicating better surface quality at optimum electrolyte concentration of 30%. FMC increases from 11.4 3 mg/m3 to 81.96 mg/m3 with increment in citric acid concentration from 10 to 50% wt./vol. due to acceleration in electrochemical reactions & higher discharge energy. FMC is 453.8% higher at 50% citric acid concentration in comparison to lower concentration of 10% indicates direct relationship between electrolyte concentration and fume production. Fume particles exhibits spherical, irregular and agglomerated morphologies with sizes in the range of 1 to 13 µm. Chemical composition analysis of fume particles reveals the presence of oxidized, organic, metallic particles, nitrogen dioxide (NO₂), methane (CH₄) and aromatic compounds. The use of a mixed Citric acid-NaCl electrolyte effectively prevents the formation of hazardous components such as sulphur compounds, titanium (Ti), chromium (Cr) and halogenated substances. These findings highlight the potential of citric acid based electrolyte as a sustainable and safer solution for precision glass machining with minimal impact on environment and operator’s health.