Study of ECMM parameter using S1 Tool steel: Optimization of performance parameters for ECMM with application of response surface methodology

The concept Electrochemical machining (ECM) is broadly implemented in manufacturing area for the past two decades because of several advantages e.g. almost negligible tool wear, resistance of W.P. to thermal and mechanical stress and strain and the ease to form complicated shapes in tough material. Several optimization techniques had been implemented for studying the process factors of different non-conventional machining processes. Analysis of surface texture by implementation of RSM had been discussed by authors but they have not included the ROC& MRR. A precise investigation of ROC and MRR is studied in detail. Our aim for the present work is to optimize the independent parameter of ECMM using S1 tool steel also called as shock resistant tool steel, for maximizing the amount of material removal and for minimizing the radial over cut using RSM. The multi-parameter examinations of the MRR and ROC obtained from RSM have been in depth analysed by contour and surface plots. Voltage is maximum effect on machining rate whereas the E.C. largely affects ROC in comparison to other parameters. The optimum performance parameters for ECMM setup are determined for future investigation.