Modelling and analysis of electrochemical machining of cast Al/20%SiCp composites

The machining characteristics of LM25 Al/20%SiC_P composite using electrochemical machining was investigated in the present study. The present paper highlights the 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 surface roughness R_a phenomena, through response surface methodology, utilising relevant experimental data as obtained through experimentation. Experimental plan is performed by a standard response surface methodology design called a central composite design. The results of analysis of variance (ANOVA) indicate that the proposed mathematical model obtained can adequately describes the performance within the limits of the factors being studied. Optimal combination of these parameters can be used in order to achieve maximum metal removal rate and minimum R_a.