Optimization of Machining Parameters in ECM of Al/B₄C Composites

Abstract

The present paper deals the application of Taguchi method with grey relational analysis to optimize the machining parameters with multiple responses in electrochemical machining (ECM) of Al/B₄C metal matrix composites. Experiments were conducted on a Metatech ECM setup and L₂₇ orthogonal array was chosen for the experiments. The electrochemical machining parameters namely applied voltage, feed rate, electrolyte concentration and reinforcement content were optimized based on multiple responses, i.e. material removal rate, surface roughness and radial over cut. The morphology of the machined surfaces was studied with scanning electron micrographs. The optimum machining parameters are calculated by using grey theory and results are compared with ANOVA. The results show that the feed rate and electrolyte concentration are the most significant parameters which affect the multiple machining responses simultaneously. Experimental results show that the responses in ECM can be improved effectively through this approach.