Modeling of Radial Over Cut in Electrochemical Machining of Al-B4C MMC Using Response Surface Methodology

Abstract

AbstractElectrochemical machining (ECM) is increasing its importance in machining of metal matrix composites (MMC) due to some specific advantages which can be exploited during machining operation. In ECM the quality of the surface produced is also depends on the workpiece physical and electrical properties along with the process parameters like voltage, feed rate, electrolyte concentration, type of electrolyte, current, gap between electrodes etc. Therefore, in the present work the percentage of reinforcement of the particulates in the matrix is considered one of the process parameters along with the applied voltage, electrode feed rate and electrolyte concentration. A mathematical prediction model of the radial over cut (ROC) was developed using response surface methodology (RSM). The effects of electrochemical machining parameters on the Radial over cut were evaluated. The contour plots were drawn to study the effect of various process parameters and their interaction. In this work the predicted values and measured values are quite close to each other. Therefore, the developed model can be effectively used to predict the radial over cut on electrochemical machining of Al-B4C composites.