Optimization Of Processing Parameters In Ecm Of Automotive Die Tool Steel Using Moga

摘要

This reserch work attempts to optimize influencing parameters during Electrochemical machining (ECM) of High corbon high chromium (HCHCr) die steel which is commonly used in automotive, metal forming and cutting industry. The selected influencing parameters are: applied voltage and electrolyte discharge rate are three levels and tool feed rate with four levels. Thirty six experiments were desiged through Design expert 7.0 software and Multi Objective Genetic Algorithm (MOGA) tool is applied to identify the optimum machining parameter conditions which turn into the best Material removal rate (MRR) and surface roughness (SR). The experimental analyses of copper (Cu) Nano particles suspended in aqueous NaNO3 solution reveal that applied voltage of 18 V, tool feed rate of 0.54 mm/min and electrolyte discharge rate of 12 lit/min would be the optimum values in ECM of HCHCr die Tool steel under the selected machining conditions, comparing to plain aqueoes NaNO3 electrolyte solution. For checking the optimality obtained from the multi objective GA in MAT LAB software, the maximum MRR of 375.782 mm~3/min and respective surface roughness Ra of 2.339um were predicted at applied voltage of 17.688 V, tool feed rate of 0.539mm/min and electrolyte discharge rate of 11.998 lit/min. Confirmatory tests showed that the actual performance at the optimum conditions were 361.214 mm~3/min and 2.41 μm, the deviation from the predicted performance is less than 4% which has proves the composite desirability of the developed models for MRR and SR at maximum MRR condition.