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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 505
STUDY OF DIFFERENT WORK MATERIALS EFFECT ON SURFACE
ROUGHNESS IN ELECTROCHEMICAL MACHINING PROCESS
Ramandeep Singh1
, Nikhil Gandotra2
, Ayyappan Solaiyappan3
1
Assistant Professor, Mechanical Department, DAV University, Jalandhar Punjab, India
2
M.tech student, Mechanical Department, DAV University, Jalandhar, Punjab, India
3
Assistant Professor, Mechanical Department, GEC, Salem, Tamilnadu, India
Abstract
In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic
dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise
selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many
unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of
process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for
experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter-
electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most
significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is
found to be most prominent on Brass work-piece.
Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass;
Aluminium; Taguchi; ANOVA.
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1. INTRODUCTION
Electrochemical machining is a controlled atomic
dissolution of work material in which material is removed
from the work piece, not in a conventional manner, but by
the combine action of two direct forms of energies i.e.
electrical and chemical. ECM process relies on the principle
of electrolysis [3]. In electrolysis, two electrodes immersed
into a liquid solution also called electrolytic solution, in
order to deplete metal from anode and plated on cathode,
when the electric current is passed between them [2].
Though, the principle of electrolysis was in use for a long
time in a process called electroplating. But with certain
modifications, ECM is often characterized as “reverse
electroplating”, with difference of no deposition of work
material on cathode.
In today’s manufacturing era, machining quality relies on
surface finish of the machined work piece to a great extent.
ECM contributed a lot to achieve good surface finish while
machining. To enhance the machining performance, precise
selection of machining parameters, is still a demanding job
in ECM process as it is very complex process involving so
many unpredictable chemical reactions while machining.
Various investigations have been carried out for improving
the surface roughness process characteristic of ECM process
by numerous researchers. Neto, J., et al. [1] took material
removal rate (MRR), surface roughness (SR) and over-cut as
response parameter for studying process variables in
electrochemical machining (ECM) of Valve-Steel. Surface
roughness decreases with increase in tool feed rate.
Ganesan, G., et al. [5] used non-dominated sorting genetic
algorithm-II (NSGA-II) to optimize ECM process.
Production rate was increased considerably by reducing
machining time Chakradhar, D., and Gopal, A., [4] found
tool feed rate as most influencing machining parameter by
performing ANOVA in investigation and optimization of
EN-31 steel, using grey relation analysis. Acharya, B.R., et
al. [6] adopted Response Surface Methodology to
investigate the effect of four machining parameters i.e.
electric current, voltage, electrolyte flow rate and inter-
electrode gap on MRR and SR. Surface roughness was
influenced greatly by current. Goswami, R., et al. [8]
reported the ECM of Mild Steel and Aluminium by using
Taguchi approach to analyze and predict optimal process
input characteristics for surface roughness and material
removal rate. For both materials, current was most
significant machining parameter for SR. Bisht, B., et al. [7]
used mild steel and aluminium as work material in ECM
process to optimize the machining performance. It was
concluded that aluminium alloy had good surface finish as
compared to mild steel. Das, M.K., et al. [9] applied
Artificial Bee Colony Algorithm for investigating
electrochemical machining of EN31 steel to optimize MRR
and SR. Scanning electron microscopy (SEM) images were
used to study surface characteristics. Surface roughness was
greatly influenced by electrolyte concentration.
Sathiyamoorthy, V., and Sekar, T., [11] used NaCl aqueous
solution in electrochemical machining of die steel and three
electrolyte jet patterns namely straight jet in circular,
inclined jet in circular and straight jet in spiral to analyze the
influence of electrolyte distribution on material removal rate
(MRR) and surface roughness (SR). Straight jet in spiral
pattern performed significantly in improving the
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 506
performance of ECM. Habib, S.S., [10] used Taguchi
approach for optimization of ECM response characteristics
viz. MRR and SR by taking voltage, tool feed rate,
electrolyte concentration and current as machining
parameters. Voltage influence MRR and current influence
SR significantly. Rao, S.R., and Padmanabhan, G., [12]
done electrochemical machining process investigation by
using utility based taguchi method. Voltage, electrolyte
concentration, electrode feed rate and percentage of
reinforcement were machining parameters influencing
MRR, SR and ROC. From ANOVA, tool feed rate was most
significant machining parameter.
In the past, various researchers have attempted to study and
optimize ECM process by taking process input parameters
such as electric current, voltage, tool feed rate, electrolyte
concentration, electrolyte flow rate, inter-electrode gap etc.
and analysing their effect on response parameters viz.
material removal rate, surface roughness, radial overcut etc.,
which decide the cutting performance. A very rare work has
been done by taking work material as input parameter for
experimental study of ECM, as performance of process also
be influenced by type of work material due to its chemical
and electrical characteristics. Inspite of other important input
parameters, work material is one of the important parameter,
which affects SR. As ECM is an atomic dissolution of work
material involving chemical reactions during machining, so
chemical characteristics of work material do affect the
response parameters.
In the current research work, an effort has been made to
study the effect of input parameters on Percentage
Improvement in Ra (% ∆Ra) by selecting work material as an
input parameter along with voltage and inter-electrode gap
as another two parameters and optimize these input
parameters to improve % ∆Ra, using hexagonal shaped
copper electrode and Taguchi method. Three different
materials i.e. Mild Steel, Brass and Aluminium are taken for
experiments which are widely used in industries.
2. EXPERIMENTAL DETAILS
2.1 Experimental Set-Up
Electrochemical machining apparatus of Metatech-Industry,
Pune was used for conducting experiments as shown in
figure-1. The ECM apparatus comprises of machining unit,
control panel, electrolyte circulation tank. Machining unit is
a tough structure, accompanied with many precise
components which help in machining. It comprises of a job
holding vice and stepper motor-electrolyte supply
arrangement where tool is fixed, which helps in the
movement of tool and electrolyte flow. Control panel act as
input device which can vary the parameters like current,
voltage and feed rate. Control panel supplies power to the
machining unit. Its main function is to run and control the
machining process. The electrolyte circulation tank is fitted
with pump which supplies the electrolyte to machining unit;
a pressure gauge for determining the electrolyte pressure and
a flow control valve for deciding the amount of flow.
Fig-1: ECM Set-up
CONTROL PANEL
MACHINING UNIT
ELECTROLYTE CIRCULATION TANK
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 507
2.2 Selection of Work-Piece Material
In the present research work, three different work materials
were chosen for experiments. The materials used were Mild
Steel, Brass and Aluminium. These are the commonly used
materials in industries for the fabrication of different
components and having very wide applications. Work-
pieces, equal number of each material, circular in shape
were taken for experiments having dimension of 30mm in
diameter and 20mm in thickness, as shown in figure-2.
Each work-piece was fabricated with the help of turning
operation. The chemical composition of work-piece sample
of mild steel, brass and aluminium used for present
investigation is as in table-1(a), 1(b) and 1(c).
Table-1(a): Chemical Composition of Mild Steel Work-piece
Element C Si Mn P S
Weight % 0.28 0.270 0.587 0.0285 0.0210
Table-1(b): Chemical Composition of Brass Work-piece
Element Cu Zn PB Sn Mn Fe Ni Si Al Sb
Weight % 56.1 39.3 3.23 0.37 0.03 0.29 0.28 0.03 0.10 0.01
Table-1(c): Chemical Composition of Aluminium Work-piece
Element Al Si Fe Cu Mn Mg Zn Cr Ti
Weight % 98.3 0.494 0.432 0.039 0.058 0.464 0.053 0.009 0.015
.
Fig-2: Pool of Work-pieces; extreme left- Mild steel, middle- Brass and extreme right- Aluminium
2.3 Tool and Electrolyte
Copper as tool was chosen for present investigation as it has
very high thermal and electrical conductivity. The
machining area of tool is hexagonal in shape; with head of
3mm thickness and 2 mm hole at Centre of hexagonal
shaped end of rod for the flow of electrolyte during
machining (refer Figure-3). For my present investigation,
NaCl is used as electrolyte and mineral water to make
electrolytic solution, since NaCl is a non-passive electrolyte
and do not affect the work-piece surface. Electrolyte
concentration has been kept constant throughout at 150g of
NaCl to 1 liter of mineral water. The various process
variables and their limits are specified as in table-2.
Fig-3: Machining area of copper tool
MILD STEEL BRASS ALUMINIUM
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 508
Table-2: Process Variables and their Limits
V.NO VARIABLES UNIT LIMITS
1 voltage V 10-18
2 current A 0-280
3 Power supply Nil DC-Continuous
4 Work-Piece Material Nil Mild Steel, Brass and Aluminium
5 Tool Material Nil Copper
6 Tool-Electrode Condition Nil Non-Rotating
7 No. of Holes in Tool Nil 1
8 Tool Feed Rate mm/min 0.1
9 Inter-Electrode Gap mm 0.2-0.6
10 Electrolyte Type Nil NaCl aqua solution
11 Electrolyte Concentration g/L 150
12 Electrolyte Flow Rate L/min 9
13 Electrolyte Temperature 0
C 28
14 Electrolyte Pressure Kg/cm2
27
15 Machining Time Min 10
3. SCHEME OF EXPERIMENT
For the present experimental work, Taguchi L9 orthogonal
array having eight degree of freedom was used. From eight
degree of freedom, six degree of freedom was assigned to
three parameters; each parameter has two degree of freedom
and two degree of freedom was assigned to the error.
According to Taguchi’s methodology, the total DOF
required for the experiment must be less than or equal to
selected OA. Nine experiments were conducted according to
selected L9 OA. Three process parameters viz. work-piece
material, voltage and inter-electrode gap (IEG) were taken
as machining parameters. The degree of influence of the
machining parameters in ECM was determined by taking,
three factors, each at three levels, with equal spacing of the
cutting parameters, as shown in Table-3. The different levels
of machining parameters were allocated in standard L9 OA
by means of linear graphs is given in Table-4.
Table-3: Machining Parameters and their Stages
MACHINING PARAMETER REPRESENTATION UNIT
STAGES
STAGE-1 STAGE-2 STAGE-3
Work-Piece Material W -
Mild Steel
(M)
Brass
(B)
Aluminium
(A)
Voltage V Volts 10 14 18
Inter-Electrode Gap G mm 0.2 0.4 0.6
Table-4: Assignment of Parameters in L9 Orthogonal Array with Response
EXP
NO.
ORDER
OF RUN
MACHINING
PARAMETERS TRIAL
CONDITIONS
RESPONSE %∆Ra
(RAW DATA)
SNR (db)
W V G R1 R2 R3
1 2 3
1 1 1 (M) 1 (10) 1 (0.2) 22.04 28.01 25.03 27.84
2 4 1 (M) 2 (14) 2 (0.4) 37.50 32.54 35.02 30.84
3 7 1 (M) 3 (18) 3 (0.6) 54.04 66.84 60.44 35.53
4 2 2 (B) 1 (10) 2 (0.4) 47.29 59.9 53.60 34.46
5 5 2 (B) 2 (14) 3 (0.6) 62.43 67.43 64.93 36.24
6 8 2 (B) 3 (18) 1 (0.2) 67.49 62.18 64.84 36.22
7 3 3 (A) 1 (10) 3 (0.6) 70.31 62.94 66.63 36.45
8 6 3 (A) 2 (14) 1 (0.2) 29.47 78.75 54.11 32.59
9 9 3 (A) 3 (18) 2 (0.4) 68.15 73.32 70.74 36.98
TOTAL 458.72 531.91 495.32
R1, R2, R3 represents response value for three experimental runs. The 1’s, 2’s, and 3’s represent stages 1, 2,
and 3 of the machining parameters. T Ra =Overall mean of ΔRa = 55.04
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 509
4. RESULTS AND ANALYSIS
From experimental data, the mean values of response
parameter and Signal-to-Noise Ratio (dB) for each
machining parameter at level one, level two and level three
(L1, L2, L3) are calculated as per in table-5. The main
effects of machining parameters both for raw data and SNR
data are plotted in figure-4 (a, b and c). The significance and
optimal conditions of machining parameters for mean
response parameter are recognized by analyzing response
curves and the ANOVA Tables.
Table-5: Mean values & main effects of Percentage improvement in surface roughness (∆Ra)
Machining
Parameter
Stage Work-piece Material Voltage IEG
Type of Data
Levels
Raw
Data
SNR
(dB)
Raw
Data
SNR
(dB)
Raw
Data
SNR (dB)
Mean Values
(SR)
S1 40.16 31.41 48.42 32.92 47.99 32.22
S2 61.12 35.64 51.35 33.22 53.12 34.10
S3 63.82 35.34 65.34 36.24 63.10 36.07
Main Effects
(SR)
S2-S1 20.96 4.24 2.94 0.31 5.13 1.88
S3-S2 2.71 -0.30 13.98 3.02 10.88 1.98
Difference {( S3-S2)-( S2-
S1)}
-18.26 -4.54 11.05 2.72 5.76 0.10
S1, S2 & S3 represent stages 1, 2, & 3 respectively of parameters. S2-S1 is the mean main effect when the
corresponding parameter varies from Stage 1 to Stage 2. S3-S2 is the main effect when the corresponding
parameter varies from Stage 2 to Stage 3.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 510
Fig- 4(a) Influence of Work-piece Material; (b) Effect of Voltage and (c) Effect of IEG on S/N ratio and percentage improvement
in Surface Roughness
The effect of Work-piece Material on Percentage
Improvement in Surface Roughness and Signal-to-Noise
Ratio is clearly visible in Figure-4(a). Figure shows that the
percentage improvement in Ra is highest when brass is used
as work-piece and lowest in case of mild steel. Percentage
improvement in Ra is almost same in case of brass and
aluminium. This is due to different characteristics of
different materials like Crystallographic irregularities, such
as dislocation. An uneven distribution of current density is
produced due to different composition of alloy, which leaves
the microscopic peaks and valleys that form poor surface
finish. More fine grained as well as homogenous structures
produce a better surface quality. It also depends on the
machining conditions and electrolyte selected for
machining.
Figure-4(b) represents the influence of voltage on Signal-to-
noise ratio (SNR) and Percentage improvement in Ra.
Percentage Improvement in Ra increases directly as the
voltage is changed from 10V to 18V. Highest percentage
improvement in Ra is obtained at 18V. The lowest
percentage improvement in Ra is observed when 10V
voltage is used. There is less increase in surface finish when
voltage changes from 10V to 14V as when voltage changes
from 14V to 18V. This is due to reason that surface finish
increases with increase in current and current increases
when voltage is increased. When the applied voltage is low,
current in the IEG is lower which leads to uneven
dissolution of material resulting higher surface roughness
and vice-versa.
One more parameter that affects the percentage
improvement in Ra is Inter-Electrode Gap. Figure-4(c)
shows the variation of percentage improvement in Ra with
respect to various values of IEG. The Figure show that the
percentage improvement in Ra increases directly and linearly
when IEG changes from 0.2mm to 0.6mm. Lower value of
percentage improvement in Ra is observed at 0.2mm IEG
and highest value of percentage improvement in Ra is
observed at 0.6mm IEG. This is due to reason that the
electrolyte used was concentrated NaCl. Salts crystallize out
of the solution at higher concentrations which increase the
MR but decrease the surface finish. So, surface finish will be
better at high IEG and high voltage using concentrated
electrolyte.
Analysis of Variance (ANOVA) was executed on
experimental data to find significance of the machining
parameters towards the Percentage Improvement in Surface
Roughness. The Pooled ANOVA of raw data and the SNR
data for percentage improvement in Ra are given in Tables-6
and 7.
Table-6: Pooled ANOVA of Raw Data for Percentage Improvement in Surface Roughness
SOURCE SS DOF V F- RATIO P%
Work-piece Material 33.50 2 16.75 32.85 43.45
Voltage 20.30 2 10.15 19.91 26.33
IEG 22.28 2 11.14 21.85 28.90
Error 1.02 20 0.51 1.32
Total (T) 77.09 26 -- 100
Significance at 95% confidence level, Fcritical =3.55
SS- Sum of Squares, DOF- Degree of Freedom, V- Variance
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 511
Table-7: Pooled ANOVA of S/N Ratio Data for Percentage Improvement in Surface Roughness
SOURCE SS DOF V F- RATIO P%
Work-piece Material 3019.30 2 1509.65 20.08 41.95
Voltage 1471.53 2 735.77 9.79 20.45
IEG 1202.88 2 601.44 8.00 16.71
Error 1503.55 2 75.18 20.89
Total (T) 7197.27 8 -- 100
Significance at 95% confidence level, Fcritical =3.55
SS- Sum of Squares, DOF- Degree of Freedom, V- Variance
From ANOVA tables, the mean and variation in percentage
improvement in surface roughness values were considerably
affected by work-piece material, voltage and IEG. The
percentage influence of work-piece material is highest
(43.45%) for improvement in surface roughness followed by
the IEG (28.90%), and voltage (26.33%). Percentage
improvement in surface roughness is considered as “higher
the better” type of quality characteristic. Therefore, higher
values of machining parameters are considered to be
optimal.
The S/N ratio analysis (refer Table-5 and Figure-4) suggests
that Second level of material of work-piece (Brass) and
Third level of voltage (18V) and IEG (0.6mm) are the
optimum levels of parameters for maximum percentage
improvement in Ra (i.e. Least Surface Roughness).
5. ASSESSMENT OF OPTIMAL VALUE OF
RESPONSE PARAMETER
The effect of the significant machining parameters helps in
assessment of optimal value of response parameter within
confidence interval. The confirmation experimentations give
the mean value of response parameter, which must lie within
the 95% confidence interval of confirmation experiment and
mean value of quality characteristic obtained from the
confirmation experiments may or may not lie within 95%
confidence interval of population.
The optimal value of ∆Ra is estimated as:
∆Ra = TGVW 2332  (1)
T̅ = overall mean of response = 55.04 (Table-4)
2W = Mean value of Ra at the 2nd level of Work-piece
Material =
61.12 (Table-5)
3V = Mean value of Ra at the 3rd level of Voltage = 65.34
(Table-5)
3G = Mean value of Ra at the 3rd level of IEG = 63.10
(Table-5)
Substituting these values in equation 1, ∆Ra = 79.48
The confidence interval of confirmation experiments (CICE)
and of population (CIPOP) is calculated by using the
following equations:







R
1
n
1
V)f(1,FCI
eff
eeαCE
(2)
eff
eeα
POP
n
V)f(1,F
CI 
(3)
Where,
Fα (1, fe) = The F-ratio at the confidence level of (1-α)
against DOF 1 and error degree of freedom fe = 4.35
(Tabulated F value)
fe = Error DOF = 20 (Table-6)
N = Total number of outcome = 27 (conduct = 9, replication
= 3)
R = Sample size for confirmation experiments = 3
Ve = Variance Error = 0.51 (Table-6)
neff =
N
1+[DOF associated in the predicted mean response ]
= 3.87
So, CICE = ± 1.146
And CIPOP = ± 0.758
The 95% confidence interval of predicted optimal range is:
Mean Ra – CICE < ∆Ra > Mean Ra + CICE
78.344 < ∆Ra > 80.626
The 95% confidence interval of the predicted mean is:
Mean Ra – CIPOP < ∆Ra > Mean Ra + CIPOP
78.722 < ∆Ra > 80.238
6. CONFIRMATION EXPERIMENT
Three confirmation experiments were performed, to
authenticate the results acquired, for response parameter i.e.
percentage improvement in Ra at the optimal levels of
Work-piece Material at Second level (W2), Voltage at level
Three (V3), and IEG which is also at Third level (G3). The
confirmation result is given in table-8. The experimental
values of percentage improvement in Surface Roughness
attained through the confirmation experiments were within
95% of confidence intervals of respective response
characteristic.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 512
Table-8: Outcome of Confirmation Experiments within Confidence Intervals
Response
Parameter
Optimal
Machining
Parameters
Predicted
Optimum
Value
95% Confidence Interval Authentic Value
(Avg. of
Confirmation
Exp.)
%age Improvement
in Ra
W2V3G3 79.48 CICE:78.344<∆Ra >80.626
CIPOP:78.722<∆Ra >80.238
79.243
CICE – Confidence interval for the mean of the confirmation experiments
CIPOP – Confidence interval for the mean of the population
7. CONCLUSION
The important conclusions from the present experimental
study are summarized below:
 Effect of machining parameters i.e. work-piece
material, voltage and inter-electrode gap (IEG) on
percentage improvement in SR was prominent.
 Work-piece material was established as most
significant factor affecting percentage improvement
in SR followed by Inter-electrode gap and Voltage.
 Highest value of Percentage Improvement was
observed in case of brass as work-piece and lowest in
case of mild steel.
 Percentage Improvement in Ra was increased linearly
in case of IEG. Highest Percentage Improvement in
Ra was observed at 0.6mm and lowest was observed
at 0.2mm.
 Percentage improvement in Ra was increased
gradually as voltage was change from 10V to 18V.
Percentage Improvement in Ra was highest at 18V
and lowest at 10V.
 The optimal set of parameters were second level of
work material (Brass), third level of voltage (18V)
and third level of IEG (0.6mm).
 Overall, it was found that characteristics of work
material influence the Improvement in Surface
Roughness as well as other operating conditions of
ECM process.
ACKNOWLEDGEMENTS
The authors appreciatively acknowledge the Technical
Education Quality Improvement Programme (TEQIP)
scheme of World Bank for funding electrochemical
machining apparatus used for experiments at Mechanical
Engineering Department of Govt. College of Engineering,
Salem, Tamilnadu, India.
REFERENCES
[1]. Neto, J., Silva, E., and Silva, M., (2006) “Intervening
variables in electrochemical machining” Journal of
Materials Processing Technology, Vol. 179, pp. 92–96.
[2]. Uttarwar, S., and Chopade, I., (2009) “Effect of voltage
variation on MRR for stainless steel EN series 58A (AISI
302b) in electrochemical machining: a practical approach”
Proceedings of the World Congress on Engineering, Vol. II,
London, U.K.
[3]. A. Moarrefzadeh, (2011) “Finite-Element Simulation of
dimensional limitation of Electro Chemical Machining
(ECM) Process" International journal of multidisciplinary
sciences and engineering, Vol. 2, NO. 7, pp. 101-107.
[4]. Chakradhar, D., and Gopal, A., (2011) “Multi-Objective
Optimization of Electrochemical machining of EN31 steel
by Grey Relational Analysis” International Journal of
Modeling and Optimization, Vol. 1, No. 2, pp. 113 – 117.
[5]. Ganesan, G., Senthilkumar, C., and Karthikeyan, R..,
(2011) “Parametric optimization of electrochemical
machining of Al/15% SiCp composites using NSGA-II”
Transaction of nonferrous metal society of China, Vol. 21,
pp. 2294−2300.
[6]. Acharya, B., Mohanty, C., and Mahapatra, S., (2013)
“Multi-objective optimization of electrochemical machining
of hardened steel using NSGA II” Procedia Engineering,
Vol. 51, pp. 554-560.
[7]. Bisht, B., Vimal, J., and Chaturvedi, V., (2013)
“Parametric Optimization of Electrochemical Machining
Using Signal-To-Noise (S/N) Ratio” International Journal of
Modern Engineering Research, Vol. 3, Issue.4, pp. 1999-
2006.
[8]. Goswami, R., Chouhan, R., and Chaturvedi, V., (2013)
“The implementation of taguchi approach on ECM process
parameters for mild steel and aluminium” International
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Vol. 3, pp. 53 – 62.
[9]. Das, M., Kumar, K., Barman, T., and Sahoo, P., (2014)
“Investigation on Electrochemical Machining of EN31 Steel
for Optimization of MRR and Surface Roughness using
Artificial Bee Colony Algorithm” Procedia Engineering,
Vol. 971, pp. 1587 – 1596.
[10]. Habib, S., (2014) “Experimental Investigation of
Electrochemical Machining Process using Taguchi
Approach” International Journal of Scientific Research in
Chemical Engineering, Vol. 1(6), pp. 93-105.
[11]. Sathiyamoorthy, V., and Sekar, T., (2014)
“Experimental studies on improving the performance of
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die steel using jet patterns” Carbon – Science and
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[12]. Rao, S., and Padmanabhan, G., (2015) “Parametric
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Technology, Vol. 10, No. 1, pp. 81 – 96.
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 513
BIOGRAPHIES
Ramandeep Singh I received
my B.tech degree from
Regional Engineering College,
Jalandhar, Punjab, India, in
1998, the M.tech degree from
Regional Engineering College,
Kurukshetra, India, in 2000 and
is pursuing my doctorate studies
from PEC University of
Technology, Chandigarh, India.
I am having more than fourteen
years of experience in industry
and teaching of graduate and postgraduate students. I am
having more than 30 research papers to my credit. Also
guided three postgraduate students.
Nikhil Gandotra received his
degree of B.tech in Mechanical
Engineering from DAVInstitute
of Engineering and Technology,
Jalandhar, Punjab, India in June
2012. He is pursuing M.tech in
Mechanical Engineering with
specialization in Production
from DAV University,
Jalandhar, Punjab, India.He is having one yearexperience in
teaching of diploma students. His areas of interest include
Non-conventional machining, Production& Industrial
engineering, Virtual manufacturing, Quality control and
improvement.

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Study of different work materials effect on surface roughness in electrochemical machining process

  • 1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 505 STUDY OF DIFFERENT WORK MATERIALS EFFECT ON SURFACE ROUGHNESS IN ELECTROCHEMICAL MACHINING PROCESS Ramandeep Singh1 , Nikhil Gandotra2 , Ayyappan Solaiyappan3 1 Assistant Professor, Mechanical Department, DAV University, Jalandhar Punjab, India 2 M.tech student, Mechanical Department, DAV University, Jalandhar, Punjab, India 3 Assistant Professor, Mechanical Department, GEC, Salem, Tamilnadu, India Abstract In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter- electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is found to be most prominent on Brass work-piece. Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass; Aluminium; Taguchi; ANOVA. --------------------------------------------------------------------***----------------------------------------------------------------- 1. INTRODUCTION Electrochemical machining is a controlled atomic dissolution of work material in which material is removed from the work piece, not in a conventional manner, but by the combine action of two direct forms of energies i.e. electrical and chemical. ECM process relies on the principle of electrolysis [3]. In electrolysis, two electrodes immersed into a liquid solution also called electrolytic solution, in order to deplete metal from anode and plated on cathode, when the electric current is passed between them [2]. Though, the principle of electrolysis was in use for a long time in a process called electroplating. But with certain modifications, ECM is often characterized as “reverse electroplating”, with difference of no deposition of work material on cathode. In today’s manufacturing era, machining quality relies on surface finish of the machined work piece to a great extent. ECM contributed a lot to achieve good surface finish while machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Various investigations have been carried out for improving the surface roughness process characteristic of ECM process by numerous researchers. Neto, J., et al. [1] took material removal rate (MRR), surface roughness (SR) and over-cut as response parameter for studying process variables in electrochemical machining (ECM) of Valve-Steel. Surface roughness decreases with increase in tool feed rate. Ganesan, G., et al. [5] used non-dominated sorting genetic algorithm-II (NSGA-II) to optimize ECM process. Production rate was increased considerably by reducing machining time Chakradhar, D., and Gopal, A., [4] found tool feed rate as most influencing machining parameter by performing ANOVA in investigation and optimization of EN-31 steel, using grey relation analysis. Acharya, B.R., et al. [6] adopted Response Surface Methodology to investigate the effect of four machining parameters i.e. electric current, voltage, electrolyte flow rate and inter- electrode gap on MRR and SR. Surface roughness was influenced greatly by current. Goswami, R., et al. [8] reported the ECM of Mild Steel and Aluminium by using Taguchi approach to analyze and predict optimal process input characteristics for surface roughness and material removal rate. For both materials, current was most significant machining parameter for SR. Bisht, B., et al. [7] used mild steel and aluminium as work material in ECM process to optimize the machining performance. It was concluded that aluminium alloy had good surface finish as compared to mild steel. Das, M.K., et al. [9] applied Artificial Bee Colony Algorithm for investigating electrochemical machining of EN31 steel to optimize MRR and SR. Scanning electron microscopy (SEM) images were used to study surface characteristics. Surface roughness was greatly influenced by electrolyte concentration. Sathiyamoorthy, V., and Sekar, T., [11] used NaCl aqueous solution in electrochemical machining of die steel and three electrolyte jet patterns namely straight jet in circular, inclined jet in circular and straight jet in spiral to analyze the influence of electrolyte distribution on material removal rate (MRR) and surface roughness (SR). Straight jet in spiral pattern performed significantly in improving the
  • 2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 506 performance of ECM. Habib, S.S., [10] used Taguchi approach for optimization of ECM response characteristics viz. MRR and SR by taking voltage, tool feed rate, electrolyte concentration and current as machining parameters. Voltage influence MRR and current influence SR significantly. Rao, S.R., and Padmanabhan, G., [12] done electrochemical machining process investigation by using utility based taguchi method. Voltage, electrolyte concentration, electrode feed rate and percentage of reinforcement were machining parameters influencing MRR, SR and ROC. From ANOVA, tool feed rate was most significant machining parameter. In the past, various researchers have attempted to study and optimize ECM process by taking process input parameters such as electric current, voltage, tool feed rate, electrolyte concentration, electrolyte flow rate, inter-electrode gap etc. and analysing their effect on response parameters viz. material removal rate, surface roughness, radial overcut etc., which decide the cutting performance. A very rare work has been done by taking work material as input parameter for experimental study of ECM, as performance of process also be influenced by type of work material due to its chemical and electrical characteristics. Inspite of other important input parameters, work material is one of the important parameter, which affects SR. As ECM is an atomic dissolution of work material involving chemical reactions during machining, so chemical characteristics of work material do affect the response parameters. In the current research work, an effort has been made to study the effect of input parameters on Percentage Improvement in Ra (% ∆Ra) by selecting work material as an input parameter along with voltage and inter-electrode gap as another two parameters and optimize these input parameters to improve % ∆Ra, using hexagonal shaped copper electrode and Taguchi method. Three different materials i.e. Mild Steel, Brass and Aluminium are taken for experiments which are widely used in industries. 2. EXPERIMENTAL DETAILS 2.1 Experimental Set-Up Electrochemical machining apparatus of Metatech-Industry, Pune was used for conducting experiments as shown in figure-1. The ECM apparatus comprises of machining unit, control panel, electrolyte circulation tank. Machining unit is a tough structure, accompanied with many precise components which help in machining. It comprises of a job holding vice and stepper motor-electrolyte supply arrangement where tool is fixed, which helps in the movement of tool and electrolyte flow. Control panel act as input device which can vary the parameters like current, voltage and feed rate. Control panel supplies power to the machining unit. Its main function is to run and control the machining process. The electrolyte circulation tank is fitted with pump which supplies the electrolyte to machining unit; a pressure gauge for determining the electrolyte pressure and a flow control valve for deciding the amount of flow. Fig-1: ECM Set-up CONTROL PANEL MACHINING UNIT ELECTROLYTE CIRCULATION TANK
  • 3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 507 2.2 Selection of Work-Piece Material In the present research work, three different work materials were chosen for experiments. The materials used were Mild Steel, Brass and Aluminium. These are the commonly used materials in industries for the fabrication of different components and having very wide applications. Work- pieces, equal number of each material, circular in shape were taken for experiments having dimension of 30mm in diameter and 20mm in thickness, as shown in figure-2. Each work-piece was fabricated with the help of turning operation. The chemical composition of work-piece sample of mild steel, brass and aluminium used for present investigation is as in table-1(a), 1(b) and 1(c). Table-1(a): Chemical Composition of Mild Steel Work-piece Element C Si Mn P S Weight % 0.28 0.270 0.587 0.0285 0.0210 Table-1(b): Chemical Composition of Brass Work-piece Element Cu Zn PB Sn Mn Fe Ni Si Al Sb Weight % 56.1 39.3 3.23 0.37 0.03 0.29 0.28 0.03 0.10 0.01 Table-1(c): Chemical Composition of Aluminium Work-piece Element Al Si Fe Cu Mn Mg Zn Cr Ti Weight % 98.3 0.494 0.432 0.039 0.058 0.464 0.053 0.009 0.015 . Fig-2: Pool of Work-pieces; extreme left- Mild steel, middle- Brass and extreme right- Aluminium 2.3 Tool and Electrolyte Copper as tool was chosen for present investigation as it has very high thermal and electrical conductivity. The machining area of tool is hexagonal in shape; with head of 3mm thickness and 2 mm hole at Centre of hexagonal shaped end of rod for the flow of electrolyte during machining (refer Figure-3). For my present investigation, NaCl is used as electrolyte and mineral water to make electrolytic solution, since NaCl is a non-passive electrolyte and do not affect the work-piece surface. Electrolyte concentration has been kept constant throughout at 150g of NaCl to 1 liter of mineral water. The various process variables and their limits are specified as in table-2. Fig-3: Machining area of copper tool MILD STEEL BRASS ALUMINIUM
  • 4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 508 Table-2: Process Variables and their Limits V.NO VARIABLES UNIT LIMITS 1 voltage V 10-18 2 current A 0-280 3 Power supply Nil DC-Continuous 4 Work-Piece Material Nil Mild Steel, Brass and Aluminium 5 Tool Material Nil Copper 6 Tool-Electrode Condition Nil Non-Rotating 7 No. of Holes in Tool Nil 1 8 Tool Feed Rate mm/min 0.1 9 Inter-Electrode Gap mm 0.2-0.6 10 Electrolyte Type Nil NaCl aqua solution 11 Electrolyte Concentration g/L 150 12 Electrolyte Flow Rate L/min 9 13 Electrolyte Temperature 0 C 28 14 Electrolyte Pressure Kg/cm2 27 15 Machining Time Min 10 3. SCHEME OF EXPERIMENT For the present experimental work, Taguchi L9 orthogonal array having eight degree of freedom was used. From eight degree of freedom, six degree of freedom was assigned to three parameters; each parameter has two degree of freedom and two degree of freedom was assigned to the error. According to Taguchi’s methodology, the total DOF required for the experiment must be less than or equal to selected OA. Nine experiments were conducted according to selected L9 OA. Three process parameters viz. work-piece material, voltage and inter-electrode gap (IEG) were taken as machining parameters. The degree of influence of the machining parameters in ECM was determined by taking, three factors, each at three levels, with equal spacing of the cutting parameters, as shown in Table-3. The different levels of machining parameters were allocated in standard L9 OA by means of linear graphs is given in Table-4. Table-3: Machining Parameters and their Stages MACHINING PARAMETER REPRESENTATION UNIT STAGES STAGE-1 STAGE-2 STAGE-3 Work-Piece Material W - Mild Steel (M) Brass (B) Aluminium (A) Voltage V Volts 10 14 18 Inter-Electrode Gap G mm 0.2 0.4 0.6 Table-4: Assignment of Parameters in L9 Orthogonal Array with Response EXP NO. ORDER OF RUN MACHINING PARAMETERS TRIAL CONDITIONS RESPONSE %∆Ra (RAW DATA) SNR (db) W V G R1 R2 R3 1 2 3 1 1 1 (M) 1 (10) 1 (0.2) 22.04 28.01 25.03 27.84 2 4 1 (M) 2 (14) 2 (0.4) 37.50 32.54 35.02 30.84 3 7 1 (M) 3 (18) 3 (0.6) 54.04 66.84 60.44 35.53 4 2 2 (B) 1 (10) 2 (0.4) 47.29 59.9 53.60 34.46 5 5 2 (B) 2 (14) 3 (0.6) 62.43 67.43 64.93 36.24 6 8 2 (B) 3 (18) 1 (0.2) 67.49 62.18 64.84 36.22 7 3 3 (A) 1 (10) 3 (0.6) 70.31 62.94 66.63 36.45 8 6 3 (A) 2 (14) 1 (0.2) 29.47 78.75 54.11 32.59 9 9 3 (A) 3 (18) 2 (0.4) 68.15 73.32 70.74 36.98 TOTAL 458.72 531.91 495.32 R1, R2, R3 represents response value for three experimental runs. The 1’s, 2’s, and 3’s represent stages 1, 2, and 3 of the machining parameters. T Ra =Overall mean of ΔRa = 55.04
  • 5. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 509 4. RESULTS AND ANALYSIS From experimental data, the mean values of response parameter and Signal-to-Noise Ratio (dB) for each machining parameter at level one, level two and level three (L1, L2, L3) are calculated as per in table-5. The main effects of machining parameters both for raw data and SNR data are plotted in figure-4 (a, b and c). The significance and optimal conditions of machining parameters for mean response parameter are recognized by analyzing response curves and the ANOVA Tables. Table-5: Mean values & main effects of Percentage improvement in surface roughness (∆Ra) Machining Parameter Stage Work-piece Material Voltage IEG Type of Data Levels Raw Data SNR (dB) Raw Data SNR (dB) Raw Data SNR (dB) Mean Values (SR) S1 40.16 31.41 48.42 32.92 47.99 32.22 S2 61.12 35.64 51.35 33.22 53.12 34.10 S3 63.82 35.34 65.34 36.24 63.10 36.07 Main Effects (SR) S2-S1 20.96 4.24 2.94 0.31 5.13 1.88 S3-S2 2.71 -0.30 13.98 3.02 10.88 1.98 Difference {( S3-S2)-( S2- S1)} -18.26 -4.54 11.05 2.72 5.76 0.10 S1, S2 & S3 represent stages 1, 2, & 3 respectively of parameters. S2-S1 is the mean main effect when the corresponding parameter varies from Stage 1 to Stage 2. S3-S2 is the main effect when the corresponding parameter varies from Stage 2 to Stage 3.
  • 6. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 510 Fig- 4(a) Influence of Work-piece Material; (b) Effect of Voltage and (c) Effect of IEG on S/N ratio and percentage improvement in Surface Roughness The effect of Work-piece Material on Percentage Improvement in Surface Roughness and Signal-to-Noise Ratio is clearly visible in Figure-4(a). Figure shows that the percentage improvement in Ra is highest when brass is used as work-piece and lowest in case of mild steel. Percentage improvement in Ra is almost same in case of brass and aluminium. This is due to different characteristics of different materials like Crystallographic irregularities, such as dislocation. An uneven distribution of current density is produced due to different composition of alloy, which leaves the microscopic peaks and valleys that form poor surface finish. More fine grained as well as homogenous structures produce a better surface quality. It also depends on the machining conditions and electrolyte selected for machining. Figure-4(b) represents the influence of voltage on Signal-to- noise ratio (SNR) and Percentage improvement in Ra. Percentage Improvement in Ra increases directly as the voltage is changed from 10V to 18V. Highest percentage improvement in Ra is obtained at 18V. The lowest percentage improvement in Ra is observed when 10V voltage is used. There is less increase in surface finish when voltage changes from 10V to 14V as when voltage changes from 14V to 18V. This is due to reason that surface finish increases with increase in current and current increases when voltage is increased. When the applied voltage is low, current in the IEG is lower which leads to uneven dissolution of material resulting higher surface roughness and vice-versa. One more parameter that affects the percentage improvement in Ra is Inter-Electrode Gap. Figure-4(c) shows the variation of percentage improvement in Ra with respect to various values of IEG. The Figure show that the percentage improvement in Ra increases directly and linearly when IEG changes from 0.2mm to 0.6mm. Lower value of percentage improvement in Ra is observed at 0.2mm IEG and highest value of percentage improvement in Ra is observed at 0.6mm IEG. This is due to reason that the electrolyte used was concentrated NaCl. Salts crystallize out of the solution at higher concentrations which increase the MR but decrease the surface finish. So, surface finish will be better at high IEG and high voltage using concentrated electrolyte. Analysis of Variance (ANOVA) was executed on experimental data to find significance of the machining parameters towards the Percentage Improvement in Surface Roughness. The Pooled ANOVA of raw data and the SNR data for percentage improvement in Ra are given in Tables-6 and 7. Table-6: Pooled ANOVA of Raw Data for Percentage Improvement in Surface Roughness SOURCE SS DOF V F- RATIO P% Work-piece Material 33.50 2 16.75 32.85 43.45 Voltage 20.30 2 10.15 19.91 26.33 IEG 22.28 2 11.14 21.85 28.90 Error 1.02 20 0.51 1.32 Total (T) 77.09 26 -- 100 Significance at 95% confidence level, Fcritical =3.55 SS- Sum of Squares, DOF- Degree of Freedom, V- Variance
  • 7. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 511 Table-7: Pooled ANOVA of S/N Ratio Data for Percentage Improvement in Surface Roughness SOURCE SS DOF V F- RATIO P% Work-piece Material 3019.30 2 1509.65 20.08 41.95 Voltage 1471.53 2 735.77 9.79 20.45 IEG 1202.88 2 601.44 8.00 16.71 Error 1503.55 2 75.18 20.89 Total (T) 7197.27 8 -- 100 Significance at 95% confidence level, Fcritical =3.55 SS- Sum of Squares, DOF- Degree of Freedom, V- Variance From ANOVA tables, the mean and variation in percentage improvement in surface roughness values were considerably affected by work-piece material, voltage and IEG. The percentage influence of work-piece material is highest (43.45%) for improvement in surface roughness followed by the IEG (28.90%), and voltage (26.33%). Percentage improvement in surface roughness is considered as “higher the better” type of quality characteristic. Therefore, higher values of machining parameters are considered to be optimal. The S/N ratio analysis (refer Table-5 and Figure-4) suggests that Second level of material of work-piece (Brass) and Third level of voltage (18V) and IEG (0.6mm) are the optimum levels of parameters for maximum percentage improvement in Ra (i.e. Least Surface Roughness). 5. ASSESSMENT OF OPTIMAL VALUE OF RESPONSE PARAMETER The effect of the significant machining parameters helps in assessment of optimal value of response parameter within confidence interval. The confirmation experimentations give the mean value of response parameter, which must lie within the 95% confidence interval of confirmation experiment and mean value of quality characteristic obtained from the confirmation experiments may or may not lie within 95% confidence interval of population. The optimal value of ∆Ra is estimated as: ∆Ra = TGVW 2332  (1) T̅ = overall mean of response = 55.04 (Table-4) 2W = Mean value of Ra at the 2nd level of Work-piece Material = 61.12 (Table-5) 3V = Mean value of Ra at the 3rd level of Voltage = 65.34 (Table-5) 3G = Mean value of Ra at the 3rd level of IEG = 63.10 (Table-5) Substituting these values in equation 1, ∆Ra = 79.48 The confidence interval of confirmation experiments (CICE) and of population (CIPOP) is calculated by using the following equations:        R 1 n 1 V)f(1,FCI eff eeαCE (2) eff eeα POP n V)f(1,F CI  (3) Where, Fα (1, fe) = The F-ratio at the confidence level of (1-α) against DOF 1 and error degree of freedom fe = 4.35 (Tabulated F value) fe = Error DOF = 20 (Table-6) N = Total number of outcome = 27 (conduct = 9, replication = 3) R = Sample size for confirmation experiments = 3 Ve = Variance Error = 0.51 (Table-6) neff = N 1+[DOF associated in the predicted mean response ] = 3.87 So, CICE = ± 1.146 And CIPOP = ± 0.758 The 95% confidence interval of predicted optimal range is: Mean Ra – CICE < ∆Ra > Mean Ra + CICE 78.344 < ∆Ra > 80.626 The 95% confidence interval of the predicted mean is: Mean Ra – CIPOP < ∆Ra > Mean Ra + CIPOP 78.722 < ∆Ra > 80.238 6. CONFIRMATION EXPERIMENT Three confirmation experiments were performed, to authenticate the results acquired, for response parameter i.e. percentage improvement in Ra at the optimal levels of Work-piece Material at Second level (W2), Voltage at level Three (V3), and IEG which is also at Third level (G3). The confirmation result is given in table-8. The experimental values of percentage improvement in Surface Roughness attained through the confirmation experiments were within 95% of confidence intervals of respective response characteristic.
  • 8. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 512 Table-8: Outcome of Confirmation Experiments within Confidence Intervals Response Parameter Optimal Machining Parameters Predicted Optimum Value 95% Confidence Interval Authentic Value (Avg. of Confirmation Exp.) %age Improvement in Ra W2V3G3 79.48 CICE:78.344<∆Ra >80.626 CIPOP:78.722<∆Ra >80.238 79.243 CICE – Confidence interval for the mean of the confirmation experiments CIPOP – Confidence interval for the mean of the population 7. CONCLUSION The important conclusions from the present experimental study are summarized below:  Effect of machining parameters i.e. work-piece material, voltage and inter-electrode gap (IEG) on percentage improvement in SR was prominent.  Work-piece material was established as most significant factor affecting percentage improvement in SR followed by Inter-electrode gap and Voltage.  Highest value of Percentage Improvement was observed in case of brass as work-piece and lowest in case of mild steel.  Percentage Improvement in Ra was increased linearly in case of IEG. Highest Percentage Improvement in Ra was observed at 0.6mm and lowest was observed at 0.2mm.  Percentage improvement in Ra was increased gradually as voltage was change from 10V to 18V. Percentage Improvement in Ra was highest at 18V and lowest at 10V.  The optimal set of parameters were second level of work material (Brass), third level of voltage (18V) and third level of IEG (0.6mm).  Overall, it was found that characteristics of work material influence the Improvement in Surface Roughness as well as other operating conditions of ECM process. ACKNOWLEDGEMENTS The authors appreciatively acknowledge the Technical Education Quality Improvement Programme (TEQIP) scheme of World Bank for funding electrochemical machining apparatus used for experiments at Mechanical Engineering Department of Govt. College of Engineering, Salem, Tamilnadu, India. REFERENCES [1]. Neto, J., Silva, E., and Silva, M., (2006) “Intervening variables in electrochemical machining” Journal of Materials Processing Technology, Vol. 179, pp. 92–96. [2]. Uttarwar, S., and Chopade, I., (2009) “Effect of voltage variation on MRR for stainless steel EN series 58A (AISI 302b) in electrochemical machining: a practical approach” Proceedings of the World Congress on Engineering, Vol. II, London, U.K. [3]. A. Moarrefzadeh, (2011) “Finite-Element Simulation of dimensional limitation of Electro Chemical Machining (ECM) Process" International journal of multidisciplinary sciences and engineering, Vol. 2, NO. 7, pp. 101-107. [4]. Chakradhar, D., and Gopal, A., (2011) “Multi-Objective Optimization of Electrochemical machining of EN31 steel by Grey Relational Analysis” International Journal of Modeling and Optimization, Vol. 1, No. 2, pp. 113 – 117. [5]. Ganesan, G., Senthilkumar, C., and Karthikeyan, R.., (2011) “Parametric optimization of electrochemical machining of Al/15% SiCp composites using NSGA-II” Transaction of nonferrous metal society of China, Vol. 21, pp. 2294−2300. [6]. Acharya, B., Mohanty, C., and Mahapatra, S., (2013) “Multi-objective optimization of electrochemical machining of hardened steel using NSGA II” Procedia Engineering, Vol. 51, pp. 554-560. [7]. Bisht, B., Vimal, J., and Chaturvedi, V., (2013) “Parametric Optimization of Electrochemical Machining Using Signal-To-Noise (S/N) Ratio” International Journal of Modern Engineering Research, Vol. 3, Issue.4, pp. 1999- 2006. [8]. Goswami, R., Chouhan, R., and Chaturvedi, V., (2013) “The implementation of taguchi approach on ECM process parameters for mild steel and aluminium” International Journal of Research in Engineering & Applied Sciences, Vol. 3, pp. 53 – 62. [9]. Das, M., Kumar, K., Barman, T., and Sahoo, P., (2014) “Investigation on Electrochemical Machining of EN31 Steel for Optimization of MRR and Surface Roughness using Artificial Bee Colony Algorithm” Procedia Engineering, Vol. 971, pp. 1587 – 1596. [10]. Habib, S., (2014) “Experimental Investigation of Electrochemical Machining Process using Taguchi Approach” International Journal of Scientific Research in Chemical Engineering, Vol. 1(6), pp. 93-105. [11]. Sathiyamoorthy, V., and Sekar, T., (2014) “Experimental studies on improving the performance of electrochemical machining of high carbon, high chromium die steel using jet patterns” Carbon – Science and Technology, Vol. 6, pp. 321 – 329. [12]. Rao, S., and Padmanabhan, G., (2015) “Parametric optimization in electrochemical machining using utility based taguchi method” Journal of Engineering Science and Technology, Vol. 10, No. 1, pp. 81 – 96.
  • 9. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 513 BIOGRAPHIES Ramandeep Singh I received my B.tech degree from Regional Engineering College, Jalandhar, Punjab, India, in 1998, the M.tech degree from Regional Engineering College, Kurukshetra, India, in 2000 and is pursuing my doctorate studies from PEC University of Technology, Chandigarh, India. I am having more than fourteen years of experience in industry and teaching of graduate and postgraduate students. I am having more than 30 research papers to my credit. Also guided three postgraduate students. Nikhil Gandotra received his degree of B.tech in Mechanical Engineering from DAVInstitute of Engineering and Technology, Jalandhar, Punjab, India in June 2012. He is pursuing M.tech in Mechanical Engineering with specialization in Production from DAV University, Jalandhar, Punjab, India.He is having one yearexperience in teaching of diploma students. His areas of interest include Non-conventional machining, Production& Industrial engineering, Virtual manufacturing, Quality control and improvement.