Machining Performance and Optimization of Process Parameters of Monel alloy 400 Using ECM Process

Monel alloy 400, a mixture of copper and nickel is widely renowned for its resistance to chemical and physical strength. This alloy is most likely among the toughest as well as least corrosive metal recognized in the industry and research fields. These qualities have increased its uses in a variety of domains such as aerospace, marine, and automotive. Because work hardens fast on its surface, Monel alloys are very difficult to cut using typical machine equipment or other procedures.The current study examines the effect of ECM method parameters like applied voltage source (V), electrolyte conc. (EC) as well as inter electrode gap (IEG) upon material removal rate (MRR), tool wear rate (TWR), including surface roughness (Ra). The basic electrolytes utilized in machining of Monel Alloy 400 are a mixture of aqueous sodium nitrate (NaNO3) & sodium chloride (NaCl). As an experimental strategy, the Box-Behnken Design (BBD) generated from response surface methodology (RSM) is utilized and effects of variables and their relationships are investigated, and process variables are adjusted.