Study on the wire electrochemical groove turning process

In this study a copper wire is proposed as a tool electrode in electrochemical groove turning process (WECGT). The working parameters, namely, radial feed rate, wire diameter, and rotational speed are investigated to study the performance criteria via MRR, groove width, and roundness error. An experimental study is presented through performing series of designed experiments. Key features of a WECGT setup that was designed and developed incorporating several unique features are also highlighted. The experimental results are statistically analyzed and mathematically modeled through response surface methodology (RSM). The mathematical model adequacies are checked using analysis of variance (ANOVA). Furthermore, optimal combination of working parameters has been evaluated to maximize MRR and minimize roundness error. The results reveal that using wire as an electrode in electrochemical turning instead of using a profiled tool proved its powerfulness to produce circular grooves. The results also demonstrate that the groove width has greatly increased by increasing the wire diameter, while it is decreased by increasing both the radial feed rate and rotational speed. Lower roundness errors are obtained by increasing both radial feed rate and wire diameter. The optimum combination of parameters setting is: radial feed rate of 0.08 mm min⁻1, wire diameter of 2.3 mm, and rotational speed of 578 rpm.