Optimization of process parameters on machining rate and overcut in electrochemical micromachining using grey relational analysis

This paper investigates the effect and parametric optimization of process parameters for Electrochemical micromachining (EMM) of 304 stainless steel using grey relation analysis. Experiments were conducted using machining voltage, pulse on-time, electrolyte concentration and tool tip shapes as typical process parameters. The grey relational analysis was adopted to obtain grey relational grade for EMM process with multiple characteristics namely machining rate and overcut. Analysis of variance was performed to get the contribution of each parameter on the performance characteristics and it was observed that electrolyte concentration and tool tip shape were the most significant process parameters that affect the EMM robustness. The experimental results reveal that, the conical with rounded electrode, machining voltage of 9V, pulse on-time of 15ms and electrolyte concentration of 0.35mole/l is the optimum combination for higher machining rate and lesser overcut. The experimental results for the optimal setting show that there is considerable improvement in the process.