Optimization of Electrochemical Machining Process on Making Multilayered Microfilter

Abstract

Optimization value of material removal rate (MRR) and overcut (OC) are important things in electrochemical machining (ECM), especially in production of multilayered Microfilter. Because ECM process can be influenced by voltage and feed rate, to detect the effect of both factors on MRR and OC, then conducted research with 3 levels of voltage (13, 15 and 17 volts), 3 levels of feed rate (5,5, 6,5 and 7,5 mm/min) and 3 times the replication of full factorial design approach (FF). Machining was done dynamically with a diameter of 4 mm copper electrode and workpiece material such as stainless steel 204. The results obtained from this research that voltage, feed rate and interaction of two factors have a significant influence on the value of MRR and overcut, where its influence are encapsulated in form of linear regression models. Besides that, the highest MRR obtained at voltage of 17 volts and feed rate 7,5 mm/min with value 6,37 × 10-4 g/s, while for the lowest overcut obtained at voltage of 13 volts and feed rate of 6,5 mm/min at 0,208 mm. Based on the analysis for both response generated optimum conditions at voltage 17 volts and feed rate of 6,5 mm/min with value of MRR 5,533 x 10-4 g/s and value of overcut 0,351 mm.