Modeling and optimization of electrochemical machining process

Aluminium and Boron carbide composite are fabricated using stir casting process and machined with electrochemical machining (ECM) process. Effects of the various machining parameters viz. voltage, feed rate, electrolyte concentration and percentage of reinforcement on the response characteristics viz. material removal rate, surface roughness and radial over cut in electrochemical machining process are investigated. Single objective optimization was done using Taguchi method and signal to noise ratios. Response characteristics are modeled using response surface methodology, fuzzy logics and neural networks. Multi objective optimization of the machining parameters of ECM process was done using grey relational analysis and desirability function analysis. Finally, validation of the results are done by conducting confirmation experiments.