Parameter optimization of ECH process for surface finish on ASTM-35 cast iron

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Abstract

This paper presents an experimental parameter optimization of electrochemical honing process (ECH) on the surface finish generation capability on cast iron of ASTM 35 with Brinell Hardness Hb 212. Taguchi orthogonal array of L9 experiment is used for optimization. Results from the main effect plot, regression analysis, correlation analysis, and interaction plots for the means indicate that best surface finish is obtained where the electric voltage is 15 V, electrolyte concentration is 20%, electrolyte pressure is 0.667 Mpa, and motor rotational speed is 60 rpm. However, significant variation is seen in the control of electric voltage as compared to the other three. Higher signal-to-noise ratio is observed on electric voltage followed by electrolyte concentration and electrolyte pressure signifying electric voltage is the determining factor. From standard deviation analysis, electrolyte pressure and electrolyte concentration are found to need close attention for better surface roughness along with electric voltage. The interaction plot for the three factors also indicates that electric voltage at highest level is more significant than the other factors. However, it is noted that the interaction of the electric voltage, electrolyte concentration, and electrolyte pressure significantly determines the effectiveness of the ECH process. Meanwhile, the level of control between electrolyte pressure and electrolyte concentration needs careful attention as the two factors work against each other.

Keywords

ECH Parameter optimization Surface finish Cast iron Taguchi method 

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.School of Mechanical and Industrial EngineeringMekelle UniversityMekelleEthiopia

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