Effect of Electrochemical Micromachining Process Parameters on Surface Roughness and Dimensional Deviation of Ti6Al4V by Tungsten Electrode

The electrochemical micromachining (ECMM) is a special form of conventional ECM process in which the tool electrode is at micro-level used to produce micro-features. This article aims to determine the parametric influence of process parameters in ECMM using Taguchi's experimental design and ANOVA. The objective variables are surface roughness (SR) and dimensional deviation (DD). Experiments were designed as per Taguchi's L16 orthogonal array (OA) by considering applied voltage (V), duty cycle (DC), feed rate (F) and frequency (f) as input parameters. Experiments carried on Ti6Al4V using sodium chloride (NaCl) salt solution with concentration 20 g/lt by producing blind holes of depth 250 mu m. Surface roughness is measured with non-contact surface roughness tester Talysurf CCI (coherence correlation interferometry) having < 0.01 nm as least count and dimensional deviation is measured with vision measuring machine. ANOVA technique is performed to get percentage influence of each process parameter on performance characteristics, and it is observed that duty cycle has more influence on surface roughness and applied voltage has more influence on dimensional deviation.