Determining the Effect of Machining Parameters on Material Removal Rate of AISI D2 Tool Steel in Electrochemical Machining Process Using the Taguchi Method

Abstract

Electrochemical machining is non-traditional machining which is commonly used to manufacture hard materials and to produce complicated shapes of irregular sizes in the product. In this paper, an experimental study is given for drilling AISI D2 tool steel. The focus of this study is to optimize machining parameters based on the Taguchi L9 orthogonal array approach to maximize material removal rate (MRR). Voltage, a concentration of the electrolyte, and gap width were selected as machining parameters of ECM (electrochemical machining) process. The signal to noise ratio (SN) and the analysis of variance (ANOVA) are statistical methods used to investigate the effects of machining parameters. As the results, the maximum MRR is 0.153 g/min obtained at voltage 48 V, electrolyte concentration at 150 g/l, and gap width at 1 mm. electrolyte concentration is the machining parameters that most influence the response.