Investigation on electrochemical machining(ECM) for optimization of surface roughness using response surface methodolgy(RSM)

Abstract

Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear. This thesis is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).By using RSM method this thesis highlight features of the development of a comprehensive mathematical model for correlating the interactive and higher-order influences of various machining parameters on the dominant machining criteria, i.e. the surface roughness. Optimal combination of these two parameters is used in order to achieve minimisation of surface roughness for optimal accuracy of shape features. In the experiment, mild steel is used as specimen. Based on the Experimental result using RSM it is shown that minimum value of surface roughness can be obtained at the optimal combination of two parameters.