Mathematical modeling and process parameters optimization of ultrasonic assisted electrochemical magnetic abrasive machining

Abstract

A new machining technique called ultrasonic assisted electrochemical magnetic abrasive machining integrates ultrasonic vibrations, electrochemical machining and magnetic abrasive finishing is used to machine and finish biomaterials more efficiently as compared to single process. This investigation highlights a novel technique for machining of hard materials in order to improve machining efficiency with hybrid process. Experimental design of Taguchi L27 and TOPSIS methods are implemented to find the optimum parameters of process. The objective is to maximize MRR and PISF and minimize PCMH simultaneously. This research investigates the interaction between input parameters (rotational speed of work piece, machining time, working gap, ultrasonic frequency time and voltage) and their effect on output characteristics of process like MRR, PCMH and PISF. The recommended settings of parameters for UEMAM process is found to be rotational speed = 600 rpm, machining time = 5 minutes, working gap = 3 mm, frequency time = 4 sec and voltage = 3 V from TOPSIS and rotational speed = 600 rpm, machining time = 15 minutes, working gap = 3 mm, frequency time = 6 sec and voltage = 4.5 V from Taguchi optimization plot. A comparison of experimental results and theoretical results have been done to validate the proposed mathematical model. The calculation results of the model showed that the maximum value of error is not more than 7.351 while comparing with experimental results, which suggests that the mathematical model is reasonable.