Multi-objective optimization of electrochemical finishing for attaining the required surface finish and geometric accuracy in the hole-making process

Abstract

Obtaining the required surface finish and geometric accuracy, together with attaining a high production rate, is a challenge in finishing the inner surfaces of steel pipes and bushes. One of the promising techniques for the reduction of the surface roughness of metal parts is electrochemical machining. In this paper, the roughness and dimensional inaccuracy of the internal surface of a CK45 steel bush were controlled electrochemically. For this, a novel electrochemical finishing setup was constructed. The effect of electric potential difference along with temperature, ow rate, and concentration of electrolyte on the process outputs, including the material removal rate, surface roughness, and dimensional accuracy, were investigated. The Box-Behnken Design was utilized to design the empirical experiments. Analysis of variance was performed to validate the experimental models. Also, multi-objective optimization was implemented using response surface methodology to achieve a predetermined level of surface roughness and dimensional accuracy, along with maximizing the material removal rate.