Investigation for controlled ellectrochemical machining through response surface methodology-based approach

Abstract This paper highlights features of the development of a comprehensive mathematical model for correlating the interactive and higher-order influences of various machining parameters on the dominant machining criteria, i.e. the metal removal rate and the overcut phenomena, through response surface methodology (RSM), utilising relevant experimental data as obtained through experimentation. This paper also highlights the various test results that also confirm the validity and correctiveness of the developed mathematical models for analyzing the effects of various process parameters on the machining rate and overcut phenomena. Optimal combination of these parameters can be used in order to achieve maximisation of the metal removal rate and the minimum overcut effects for optimal accuracy of shape features.