Machining of 304 stainless steel Using Electrochemical Machining (ECM) Process: Response Surface Methodology Approach

Abstract

In this study, Electrochemical Machining (ECM) of 304 stainless steel was applied by using Response Surface Methodology (RSM) approach for designing, analyzing, and mathematical modeling of ECM of 304 stainless steel. Electrolyte type, concentration, and current were the machining parameters. A mathematical model was provided for responses based on electrolyte types including Sodium Chloride (NaCl), Sodium Nitrate (NaNO3), and Potassium Chloride (KCl). The results showed that current had the highest effect on Surface Roughness (SR) and Material Removal Rates (MRR), compared to other selected factors, and it enhanced their values up to 0.465μm and 0.425gr/min, respectively. Electrolyte concentration had the highest effect on Over Cut (OC) and increased its values. The optimum condition characterized by 0.4006gr/min MRR, 0.75mm OC, and 0.465m SR was achieved with NaCl electrolyte, 1 molarity concentration, and 55 A current.