Experimental Investigation to Improve Metal Removal Rate (MRR) and Surface Roughness in Electrochemical Machining

Abstract

Electrochemical machining (ECM) is a non-traditional machining processwhich is the controlled removal of metal by anodic dissolution in an electrolyticcell in which the workpiece is the anode and the tool is cathode. In ECM, metalremoval rate (MRR) takes place due to atomic dissolution of work material.Electrochemical dissolution is governed by Faraday’s laws.I n this study the ECMis used to remove metal from the internal hole of the workpiece from aluminumalloy using NaCl solution. The rates of improvement in MRR are (6.48, 1.81, 3.74,13.24, 3.11) % for current densities of (2.82, 4.24, 5.65, 7.07, 8.48) A/cm2respectively, when compared with the stationary tool, and the rotating electrodegives better surface finish than the stationary electrode, were the enhancement ratesin roughness are (7, 31.72, 7.91, 15.49, 1.34)% for current density values of (2.82,4.24, 5.65, 7.07, 8.48) A/cm2 respectively.