Optimization of Surface Roughness for Al-alloy in Electro-chemical Machining (ECM) using Taguchi Method

Abstract

Electro-chemical Machining is  significant  process to remove metal with using  anodic dissolution. Electro-chemical machining use to removed metal workpiece from (7025) aluminum alloy using Potassium chloride (KCl) solution .The tool used was made from copper. In this present the optimize processes input parameter use are( current, gap and electrolyte concentration) and surface roughness (Ra) as output .The experiments on electro-chemical machining with use current (30, 50, 70)A, gap (1.00, 1.25, 1.50) mm and electrolyte concentration (100, 200, 300) (g/L).  The method (ANOVA) was used to limited the large influence factors affected on surface roughness and found the current was the large influence factors  with (72.17%) . The results of the optimization of comparison of experimental and prediction conditions current at level-1(30 A) , gap at level-1 (1.00mm ) and electrolyte concentration at level-1(100(g/L)) shown the average experiments and prediction surface roughness (1.352) and (1.399) respectively..