Towards higher accuracy for ECM hybridized with low-frequency vibrations using the response surface methodology

The present work addresses the improvement of machining accuracy in ECM by hybridizing the process by low-frequency vibrations. The study highlights the development of mathematical models for correlating the inter relationships of various machining parameters such as applied voltage, feed rate, back pressure and vibration amplitude on overcut and conicity for achieving high controlled accuracy. This work is based on the response surface methodology (RSM) approach. This investigation also highlights the various test results that confirm the validity and correctiveness of the developed mathematical models for analyzing the effect of the various process parameters on the overcut and conicity. Experimental results reveal useful relationships between the low-frequency vibration parameters and the ECM inter-electrode gap and hence the overcut phenomenon.