Modelling and analysis of hybrid electrochemical turning-magnetic abrasive finishing of 6061 Al/Al2O3 composite

This paper integrates the electrochemical turning (ECT) process and magnetic abrasive finishing (MAF) to produce a combined process that improves the material removal rate (MRR) and reduces surface roughness (SR). The present study emphasizes the features of the development of comprehensive mathematical models based on response surface methodology (RSM) for correlating the interactive and higher-order influences of major machining parameters, i.e. magnetic flux density, applied voltage, tool feed rate and workpiece rotational speed on MRR and SR of 6061 Al/Al₂O₃ (10% wt) composite. The paper also highlights the various test results that also confirm the validity and correctness of the established mathematical models for in-depth analysis of the effects of hybrid ECT- MAF process parameters on metal removal rate and surface roughness. Further, optimal combination of these parameters has been evaluated and it can be used in order to maximize MRR and minimize SR. The results demonstrate that assisting ECT with MAF leads to an increase machining efficiency and resultant surface quality significantly, as compared to that achieved with the traditional ECT of some 147.6% and 33%, respectively.