Optimization and Experimental Investigation on EN19 Using Hexagonal Shaped Electrode in ECM

Abstract

Electrochemical machining (ECM) has inaugurated itself as one of the major other possible way to conventional methods for machining hard materials and complicated outlines not having the residual stresses and tool wear. Electrochemical machining has vast application in automotive, Aircraft, petroleum, aerospace, textile, medical and electronic industries. Studies on Material Removal Rate (MRR) are of extremely important in ECM, since it is one of the factors to be Determined in the process decisions. So the aim of present work is to investigate the metal removal rate, over-cut diameter and surface roughness of EN19 alloy steel of diameter 13cm as work piece by using hexagonal shaped Brass electrode and brine solution as electrolyte by using Taguchi approach, then optimizing to find best setting of process variables for higher MRR, lower surface roughness and over-cut. Three parameters were chosen as process variables are: voltage, tool Feed rate and Electrolyte concentration.

Result shows that
1) Among 3 factors feed rate is effecting MRR most then comes voltage and at last electrolyte concentration.
2) For surface roughness, feed rate effects it most then concentration and at last voltage.
3) Tool feed rate effects most to over cut at second rank is voltage and at third rank is concentration which affects most to over-cut.
4) In optimizing the quality loss function, it is found that experiment run no 5 is most optimal i.e. voltage=10V, tool feed rate= 0.4 mm/min and electrolyte concentration =22.03g/l for maximizing MRR and minimizing both over-cut and surface roughness.