The Effect of Voltage on Material Removal Rate in the ECM Process
Received: 18 March 2025 | Revised: 5 April 2025 | Accepted: 19 April 2025 | Online: 4 June 2025
Corresponding author: Nagham Ghanim Ghazi
Abstract
The development of machining processes, such as Electrochemical Machining (ECM), has improved manufacturing complex shapes and complicated materials. This research investigates the enhancement of the ECM process to achieve the highest quality of materials. Specifically, Material Removal Rate (MRR) is utilized as a performance parameter to reduce machining time and increase productivity without influencing product quality. This is accomplished through machining a workpiece made of high-speed steel AISI M2, using a copper tool in a sodium chloride (NaCl) solution. Optimal voltage parameters are determined to address issues, such as surface defects, power consumption, and process instability. The primary goal of this research are to enhance surface quality and ensure precision machining. The experiment includes three parameters, each one at three levels: voltage (10 V, 20 V, and 30 V), electrolyte concentration (20 g/L, 40 g/L, and 60 g/L), and a gap width (0.1 mm, 0.2 mm, and 0.3 mm). The experimental work is carried out on Minitab, a statistical software with a general full factorial design. A mathematical model is developed to create a figure through which is determined how MRR performs with variation of the three experiment parameters. Analysis of variance is performed through the ANOVA test to study the influence of the input parameters. The results indicate that MRR is significantly affected by voltage, followed by electrolyte concentration, while the gap width demonstrated minimal effect. Increasing voltage and electrolyte concentration leads to an increase in MRR. Similarly, increasing the gap width initially leads to a decrease in MRR, which then reaches a plateau. The maximum and minimum MRR values are 0.0871 g/min and 0.0023 g/min, respectively, revealing that voltage is an effective parameter for ECM quality optimization.
Keywords:
electrochemical machining, material removal rate, electrolyte, minitab, ANOVADownloads
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