Experimental Investigation to Improve Metal Removal Rate (MRR) and Surface Roughness in Electrochemical Machining

Abstract

Electrochemical machining (ECM) is a non-traditional machining process which is the controlled removal of metal by anodic dissolution in an electrolytic cell in which the workpiece is the anode and the tool is cathode. In ECM, metal removal rate (MRR) takes place due to atomic dissolution of work material. Electrochemical dissolution is governed by Faraday's laws.I n this study the ECM is used to remove metal from the internal hole of the workpiece from aluminum alloy using NaCl solution. The rates of improvement in MRR are (6.48, 1.81, 3.74, 13.24, 3.11) % for current densities of (2.82, 4.24, 5.65, 7.07, 8.48) A/cm 2 respectively, when compared with the stationary tool, and the rotating electrode gives better surface finish than the stationary electrode, were the enhancement rates in roughness are (7, 31.72, 7.91, 15.49, 1.34)% for current density values of (2.82, 4.24, 5.65, 7.07, 8.48) A/cm 2 respectively.