Influence of Electrolyte Concentration on Metal Removal Rate and Surface Finish Quality in Electrochemical Machining Masking

Abstract

Electrochemical machining (ECM) is a specialized and precise manufacturing technique involving selective metal removal to achieve the desired shape or form. This article’s primary focus is examining the technical facets associated with the procedure. The elements mentioned encompass the system’s design and optimization, the electrolyte solution’s careful selection, and the precise control of the etching parameters. When considering the overall framework, it is essential to consider important factors such as the concentration of electrolytes, the operational voltage, and the value of the current flowing through the system. The main objective of this study is to evaluate the influence of different concentrations of sodium chloride electrolyte on the metal removal rate (MRR). This will be achieved by utilizing a direct current power supply. The present investigation used aluminum, steel, and stainless steel materials as the substrate for experimentation. These materials were selected to have identical dimensions for the anode and cathode. The main objective of this study is to evaluate the influence of varying concentrations (0.5, 1, 1.5, and 2 mole/liter) of sodium chloride electrolyte on the material removal rate and surface roughness. The findings have been disclosed, revealing the utmost removal rate for aluminum, steel, and stainless-steel materials across all levels of electrolyte concentration. The experimental information is currently presented, related to the rates of metal removal at various electrolyte concentrations of 2 moles per liter. The rates of mass loss observed in aluminum are comparatively higher when compared to those surveyed in steel and stainless steel. The roughness of a machined surface is inversely proportional to the concentration of the electrolyte.