Optimization of process parameters during electrochemical machining

Abstract

Electrochemical machining is one of the most efficient machining processes due to its ability to produce completely stress-free machined components without any need of further finishing process. However, the right understanding of the effects of key factors during machining of various materials is very important to carry out the machining. It is one of the most efficient way of cutting present in modern era. This present paper deals with the electrochemical machining of Nimonic 80A. Design of the experiments are done by using response surface methodology to study the material removal rate and surface roughness. Process parameters such as voltage, tool feed rate, inter-electrode gap and electrolyte concentration has been optimized by using the ANOVA. The regression models are developed to be used as predictive tools. The confirmation test was conducted to validate the results achieved by GRA approach. This research work helps the industrialist for selecting parameters to attain desired outputs.