Prediction of Surface Roughness and Material Removal Rate in Electrochemical Machining Using Taguchi Method

Abstract

Electrochemical machining is one of the widely used non-conventional machining processes to machine complex and difficult shapes for electrically conducting materials, such as super alloys, Ti-alloys, alloy steel, tool steel and stainless steel. Use of optimal ECM process conditions can significantly reduce the ECM operating, tooling, and maintenance cost and can produce components with higher accuracy. This paper studies the effect of process parameters on surface roughness (Ra) and material removal rate (MRR), and the optimization of process conditions in ECM. Experiments were conducted based on Taguchi’s L9 orthogonal array (OA) with three process parameters viz. current, electrolyte concentration, and inter-electrode gap. Signal-to-noise (S/N), the analysis of variance (ANOVA) was employed to find the optimal levels and to analyze the effect of electrochemical machining parameters on Ra and MRR. The surface roughness of the workpiece was decreased with the increase in current values and electrolyte concentration while causing an increase in material removal rate. The ability of the independent values to predict the dependent values (R2) were 87.5% and 96.3% for mean surface roughness and material removal rate, respectively.

Investigation and optimization of machining parameters in electrochemical machining of aluminium metal matrix composites

“…The aluminum alloy was melted, and B4C powder mixture was preheated at 750°C for 1 hour to eject gases and moisture to escape from the particle surface. [24]. The preheated B4Cparticle powder (7.5%) was added to the melted material.…”

Influence of Cutting Parameter on Scarface Quality in Dry Turning of Different Materials

“…The purpose of this investigation is to analyse experimentally the impact of parameters of the machining on the Ra in turning processes in order to create the ideal settings of these parameters to improve the roughness in turning processes. Abbas F. Ibrahim [10] examines the relationship between surface roughness and process variables (approach angle, tip radius, cutting speed, and feed rate) in a lathe. The tests were carried out using Taguchi's L8 vertical matrix to be evaluated with contrast analysis and signal-to-noise ratio.…”