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Microchannel Fabrication on Silica Glass and Experimental Investigation of MHD Convection in ECDM Process

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Abstract

Various applications of space and medical industries require microchannels, which are generally fabricated on nonconducting material, especially glass. ECDM is preferable for microfluidic channel fabrication because of lower thermal damage. Much work has already been done in ECDM for parametric analysis, which elaborates discharge regime characteristics but cannot accurately control the hydrodynamic regime. This work uses high-speed images to discuss the effect of magnetohydrodynamic convection (MHD) convection in ECDM for microfluidic channel fabrication. Experiments were conducted on an in-house developed ECDM setup to investigate the effect of magnetic field strength on WOC, bubble formation, growth, and electrolyte steering. A high-speed camera records the image of bubble and gas film formation with and without MHD convection to understand the mechanism under a magnetic field. Experimental results showed that MHD convection induced due to magnetic field improved electrolyte steering and width of cut. To find the optimal parameters, various nontraditional algorithms, i.e., particle swarm optimization, differential evolution, teaching learning-based optimization, GA, and Rao algorithms, were also applied and compared with the optimal results of response parameters. The optimum value of the material removal rate and width of the cut were seen to be the same; however, the iteration necessary to reach the optimal solution differed. The optimum voltage, concentration, duty cycle, and magnetic strength settings are 42 V, 20%, 60%, and 0.25mT, respectively.

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Acknowledgements

The author(s) would like to thank Indian Institute of Technology Roorkee(IITR), Uttarakhand, India for providing valuable lab support for conducting experiments

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The authors declare that no funds, grants, or other support were received during the preparation of this manuscript.

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  1. Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, Uttarakhand, India

    Dilip Gehlot, Pradeep Kumar Jha & Pramod Kumar Jain

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  1. Dilip Gehlot
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  2. Pradeep Kumar Jha
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  3. Pramod Kumar Jain
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The corresponding authors completed the experiments and did all the analyses related to this paper. The written work and review of the manuscript were done by another second. The third author raises the idea of paperwork and writes the conclusion and abstract.

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Correspondence to Dilip Gehlot.

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Gehlot, D., Jha, P.K. & Jain, P.K. Microchannel Fabrication on Silica Glass and Experimental Investigation of MHD Convection in ECDM Process. Silicon 16, 2521–2531 (2024). https://doi.org/10.1007/s12633-024-02859-3

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