Multi-objective optimization of electrochemical finishing for attaining the required surface finish and geometric accuracy in the hole-making process

Obtaining the required surface finish and geometric accuracy together with attaining high production rate is a challenge in finishing of the inner surfaces of steel pipes and bushes. One of the promising techniques for finishing the surface of metal parts is electrochemical machining. In this paper, the surface roughness and dimensional inaccuracy of the inner surface of a CK45 steel bush were controlled electrochemically. For this, a special electrochemical finishing machine was constructed. The effect of electric potential difference along with temperature, flow rate and concentration of electrolyte on the material removal rate, surface roughness and dimensional accuracy were investigated. Box Behnken design (BBD) was used for designing the experiments. Analysis of variance (ANOVA) was performed for validating the experimental models. Also, multi-objective optimization was performed using response surface methodology (RSM) to achieve a predetermined level of surface roughness and dimensional accuracy along with maximizing the material removal rate.