Parametric and Statistical Investigation of Material Removal Rate and Surface Roughness in Electrochemical Turning

Abstract

Electrochemical turning (ECT) is a non-traditional machining process used for shaping electrically conductive materials with high dimensional accuracy and superior surface integrity. Unlike conventional turning, ECT eliminates tool wear, cutting forces, and thermal damage by removing material through controlled anodic dissolution in an electrolyte medium. In this study, cylindrical workpieces made of High Manganese Austenitic Steel alloy were machined on a conventional lathe adapted for ECT using a Sodium chloride (NaCl) solution as electrolyte and a rectangular copper cathode tool. This work investigates the influence of three process parameters each one at three levels: electrolyte concentration (10,15 and 20g/L), applied voltage (11,18 and 25 V), and workpiece rotational speed (180,250 and 355 RPM) on the material removal rate (MRR) and surface roughness (Ra). A statistically designed experimental study is conducted to reveal the relationships between operational parameters and machining performance, a minimum Ra was about 1.7 μm results indicate that the most influential factor affecting Ra was the electrolyte concentration, followed by the rotational speed, while the applied voltage exhibited the least effect, The highest MRR value obtained was 0.0496 g/min, with applied voltage exhibiting the dominant influence on material removal performance, followed by electrolyte concentration and, finally, rotational speed.