Multi-response optimization of electrochemical micromachining parameters for SS304 using polymer graphite electrode with NaNO3 electrolyte based on TOPSIS technique

Abstract

This research experimentally investigates the influence of electrochemical micromachining (ECMM) process parameters of SS304 alloy with “polymer graphite electrode (PGE),” employing sodium nitrate as the electrolyte solution. The machining parameters were considered based on their significance in machining such as machining voltage, duty cycle and electrolyte concentration to assess and evaluate their effect on response parameters such as material removal rate, over cut and taper angle. The experimental results revealed that 23 g/l of electrolyte concentration, machining voltage of 9 V and 55% duty cycle are considered as the optimal parameters for accessing the multi-response characteristics in ECMM process with hole within the aspect ratio 0.8 micron meters. The experimental results indicated that the multi-response characteristics considered in electrochemical micromachining of SS304 alloy are enhanced using TOPSIS optimization methodology. ANOVA is used to analyze the process parameters and to identify the best contributing factor in chosen limited parameters. The results indicated that voltage is the most influencing factor which contributes 52.29%. The research possibilities of using PGE electrode are discovered for electrochemical micromachining.