Performance analysis of wire electrochemical turning process—RSM approach

Abstract

Electrochemical machining (ECM) has become one of the most widely spread techniques of the non-traditional processes. The main problem of ECM is that of choosing the correct working parameters to attain a high degree of accuracy under fine surface finish conditions. Recently, electrochemical turning has gained attention as a finishing process. By feeding a shaped tool into a rotating workpiece, axially symmetric turned parts can be manufactured. In this way, large symmetric workpiece can be made with small tools. This paper discusses the feasibility of using a wire as a tool in electrochemical turning process (WECT). The present study measures the performance criteria of the WECT process through investigating the effect of working parameters, namely, applied voltage, wire feed rate, wire diameter, workpiece rotational speed, and overlap distance, on metal removal rate, surface roughness, and roundness error. The experimental results are statistically analyzed and modeled through response surface methodology. The regression model adequacies are checked using analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated to maximize metal removal rate and minimize surface roughness and roundness error. The study reveals the ability of using a wire as a tool in WECT and its productivity; the shape errors can be controlled through the mentioned input parameters. The results show that the increase of wire feed rate enhances the productivity of the process and improves both surface quality and roundness error. Also, the increase of rotational speed improves both the productivity of the process and geometrical error of the produced parts.