Optimisation of electrochemical drilling process using Taguchi method and regression analysis

Abstract

Inconel 718 is a hard to machine nickel-based super alloy. It is extensively used in aerospace industries. It has high-strength and poor thermal diffusion which results in decreased life of tool and difficulty in machining by traditional methods. Unconventional machining processes have evolved over a period to meet such demands and claim to be a suitable alternative to conventional machining. Electrochemical machining (ECM) is an unconventional manufacturing process which is used to machine hard to machine materials. This paper presents an investigation on the application of Taguchi's approach and regression model to optimise the electrochemical drilling process of Inconel 718. The trials are planned using design of experiments proposed by Taguchi. Analysis of variance (ANOVA) is employed to determine the significance of input variables on the desired performance measures. The control of form and orientation errors of machined surfaces needs attention and included as desired performance. Multiple regression models have been developed to predict the desired performance measures in electrochemical drilling of Inconel 718.