On Machining Profile Accuracy in the Modified Electrochemical Machining Process

Numerous studies have been published on conventional electrochemical machining with different tools and workpiece materials, machining parameters, and machining profile accuracy. Also, some studies have been reported on modified electrochemical machining to address the tool replica issues in conventional electrochemical machining with a novel 3D-printed thermoplastic-based inter-electrode slit between the tool and the W/P. But hitherto, little has been reported on the aspect ratio, and machining profile accuracy (overcut) in modified electrochemical machining. This study outlines the machining profile accuracy of modified electrochemical machining with the use of a novel square profile/cross-section inter-electrode slit along with feed rate, slit thickness, tool, workpiece material, and voltage based on Taguchi L₁₈ orthogonal array. The machining profile accuracy of the cavity was ascertained in the form of the cavity dimensions along the X and Y axis, machined area, machining depth (Z), diagonal length (DL) of profile section, aspect ratio (DL/Z), and overcut. The study suggests that as per the multi-factor optimization approach for machining profile accuracy, the optimized settings of modified electrochemical machining are electrolyte concentration 100 g/l, voltage 21 V, workpiece/tool as Cu, feed rate 108 µm/min, inter-electrode slit thickness 4.5 mm with composite desirability 0.944. Further, at optimized settings of the modified electrochemical machining process in the present case study, porosity 23.95%, DL 10.955 mm, cavity length along the X-axis 4.817 mm, Y-axis 3.613 mm, and Z-axis 1.179 mm, aspect ratio of 9.29 and over cut 18.59 mm² was achieved.