Experimental Studies on Material Removal Rate of Die Steel in Electrochemical Micromachining Process Using Taguchi Method

Electrochemical micromachining is one of a commonly used unconventional machining processes used to machine the not easy to process materials and to make complicated and irregular shapes of a product. This study aims to optimize process parameters and to maximize the material removal rate (MRR). Taguchi approach is used to do the design of experiments. In this work, an experimental study is given for machining of D2 Die steel. Voltage, electrolyte concentration, and duty cycle are selected as processing parameters of the electrochemical micromachining (ECCM) process. The analysis of variance (ANOVA) and the signal-to-noise ratio (SN) are statistical methods used to study the influence of process parameters over the results. As the results, the maximum MRR is 0.1483 mm3/min achieved at the voltage of 20 V, electrolyte concentration at 150 g/l, and duty cycle at 60% in this work voltage is the most influencing parameter on the material removal rate.