This paper demonstrates a systematic approach for achieving comprehensive mathematical models for electrochemical machining (ECM) of 321-stainless steel based on the response surface methodology (RSM). Machining voltage, tool feed rate, electrolyte flow rate and concentration of NaNO3 solution were considered as the machining parameters while material removal rate (MRR) and surface roughness (Ra) were considered as the process responses. Experimental plan was performed by a central composite design (CCD).
The proposed mathematical models statistically have been evaluated by analysis of variance (ANOVA). Analysis shows that the RSM method has been appointed properly as the design of experiments (DOE) method for resolving curvature in ECM process responses. Also, the optimal machining parameter for single optimization of MRR and Ra is determined by desirability function. The results showed that the proposed approach is an effective and suitable way for modeling and optimization of the ECM machining process.