Abstract
Selection of appropriate machining parameters which result in desired outcomes plays a key role in effective utilization of the electrochemical machining (ECM) process. In this paper, in order to correlate between ECM process parameters and cost functions, comprehensive mathematical models were first determined based on response surface methodology (RSM). Voltage, tool feed rate, electrolyte flow rate and concentration of NaNO3 solution were considered as the machining parameters while material removal rate (MRR) and surface roughness (Ra) were considered as cost functions. To do this, three scenarios of machining performances, Ra≤0.9µm, 0.9µm≤Ra≤ 1.8µm, and 1.8µm≤Ra≤2.7µm, were considered for optimization search based on desirability functions. The goal is to find the optimum set of machining parameters in order to maximize the MRR while keeping Ra in specified ranges simultaneously. The results show that the errors between experimental and anticipated optimal values are less than 8.16% and hence confirm the effectiveness of the proposed approach. Keywords − − , , ,
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