Multiple-response optimisation of electrochemical grinding characteristics through response surface methodology

This paper comprehensively evaluates the influence of voltage and cutting speed on electrochemical grinding of composite carbide inserts. A complete 4(2) factorial experiment was planned and carried out where each treatment combination has been replicated twice to achieve an acceptable degree of precision. Mathematical models have been developed for the major performance indices like current density, material removal rate (MRR) and surface finish of the job by multiple linear regression analysis. Then multiple-response optimisation has been carried out to find the optimum parameter settings to get a desired yield both by desirability functions as well as by contour overlapping method. It has been found that passivation occurs increasingly at higher voltages and it is removed almost instantaneously at higher speed leading to higher current density and MRR. The surface finish is not very much dependent on grinding speed. The optimum surface finish is obtainable at 12 to 13 V (app.) in electrochemical grinding of composite carbides.