EXPERIMENTAL INVESTIGATIONS ON THE ELECTROCHEMICAL MACHINING OF D3 DIE STEEL MATERIAL AND MULTI-OBJECTIVE PARAMETER OPTIMIZATION

Abhinao Anand Singh, Rakesh Kumar Singh, Ashok Kumar Yadav, Abhijit Saha, Ashish Dewangan and Bhupender Singh
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Abhinao Anand Singh: Department of Mechanical Engineering, Noida Institute of Engineering and Technology, Greater Noida 201306, India
Rakesh Kumar Singh: Department of Mechanical Engineering, Noida Institute of Engineering and Technology, Greater Noida 201306, India
Ashok Kumar Yadav: ��Department of Mechanical Engineering, Raj Kumar Goel Institute of Technology, Ghaziabad 201003, India
Abhijit Saha: ��Department of Mechanical Engineering, Haldia Institute of Technology, Haldia 721657, India
Ashish Dewangan: �Department of Mechanical Engineering, Galgotias College of Engineering and Technology, Greater Noida 201306, India
Bhupender Singh: �Mechanical Engineering Department, JC BOSE University of Science and Technology, YMCA Faridabad, India

Surface Review and Letters (SRL), 2024, vol. 31, issue 09, 1-12

Abstract: The removal of metal in the form of sludge can be termed an ECM process, having primary salient features consisting of the tool, workpiece, power supply and electrolyte solution. ECM is a potential nontraditional machining process that includes too many factors contributing to process performance. Therefore, obtaining optimal factor combinations for higher efficiency is complex. In this research work, machining parameters are voltage, powder concentration and electrolyte concentration, based on which material removal rate (MRR) and surface roughness (SR) are derived. Regression analysis, signal-to-noise ratios and analysis of variance (ANOVA) are performed to determine the optimal levels and to examine the effects of machining parameters on MRR and SR. The results derived from the experiments noticed that the MRR decreases when the voltage level is increased and surface roughness decreases for the applied voltage. In case of an increase in powder concentration, MRR decreases from range 4 to 6 and further reduces to 6–8. In case of SR, it additionally decreases on the maximum level of powder concentration. In electrolyte concentration, the MRR decreases on the increment of electrolyte and increases after a short period of time; simultaneously SR is increased from range value 10–20 and decreased with a maximum level 20–30 of NaCl solution. A comparison of MOORA-PCA and TOPSIS-PCA demonstrates the superiority of TOPSIS over MOORA technique. Statistical results (95% confidence level) indicate that the voltage, powder concentration, and electrolyte concentration affect the surface roughness by 69.50%, 8.67% and 14.59% in the electrochemical machining of d3 die steel. Therefore, the optimum combination of process parameters corresponding to voltage: 45V, powder concentration: 4g/L, and electrolyte concentration: 10NaCl/L, respectively, were found to yield the desired result. The prediction accuracy of the TOPSIS-PCA hybrid approach model is found better than MOORA-PCA technique.

Keywords: ECM; material removal rate; surface roughness; powder concentration (Cu); electrolyte (search for similar items in EconPapers)
Date: 2024
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DOI: 10.1142/S0218625X24500744

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