Developing Empirical Relationships to Predict MRR and Overcut of ECM of EN38 Steel

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Electrochemical machining (ECM) has been increasingly recognized for the potential of machining, while the precision of the machined profile is a concern of its application. This paper describes the development of a second order, non-linear mathematical model for establishing the relationship among machining parameters such as applied voltage, electrolyte flow rate and tool feed rate with the dominant machining process criteria, namely material removal rate (MRR) and  overcut (O.C). The model is developed based on response surface methodology (RSM) using the relevant experimental data, which are obtained during an ECM operation. The results of analysis of variance (ANOVA) indicate that the proposed mathematical model obtained can adequately describe the performance within the limits of the factors being studied. The contour plots are generated to study the effect of process parameters as well as their interactions
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Electro Chemical Machining (ECM); Response Surface Methodology (RSM); Metal Removal Rate (MRR); Overcut (O.C)

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