Int J Adv Manuf Technol
DOI 10.1007/s00170-006-0759-0
ORIGINAL ARTICLE
Investigation into electrochemical micromachining (EMM)
through response surface methodology based approach
Jagannath Munda & Bijoy Bhattacharyya
Received: 8 May 2006 / Accepted: 22 August 2006
# Springer-Verlag London Limited 2006
Abstract Electrochemical micromachining (EMM) could
be used as one the best micromachining technique for
machining electrically conducting, tough and difficult to
machine material with appropriate machining parameters
combination. This paper attempts to establish a compre-
hensive mathematical model for correlating the interactive
and higher-order influences of various machining parame-
ters, i.e. machining voltage pulse on/off ratio, machining
voltage, electrolyte concentration, voltage frequency and
tool vibration frequency on the predominant micromachin-
ing criteria, i.e. the material removal rate and the radial
overcut through response surface methodology (RSM),
utilizing relevant experimental data as obtained through
experimentation. Validity and correctiveness of the devel-
oped mathematical models have also been tested through
analysis of variance. Optimal combination of these pre-
dominant micromachining process parameters is obtained
from these mathematical models for higher machining rate
with acuuracy. Considering MRR and ROC simultaneously
optimum values of predominant process parameters have
been obtained as; pulse on/off ratio, 1.0, machining voltage,
3 V, electrolyte concentration, 15 g/l, voltage frequency of
42.118 Hz and tool vibration frequency as 300 Hz. The
effects of various process parameters on the machining rate
and radial overcut are also highlighted through different
response surface graphs. Condition of machined micro-
holes are also exhibited through the SEM micrographs in
this paper. Pulse voltage pattern during electrochemical
micromachining process has been analyzed with the help of
voltage graphs. Irregularities in the nature of pulse voltage
J. Munda : B. Bhattacharyya (*)
Jadavpur University,
Kolkata, West Bengal, India
e-mail: bb13@rediffmail.com
pattern during electrochemical micromachining have been
observed and the causes of these irregularities are further
investigated.
Keywords Electrochemical micomachining (EMM) .
Metal removal rate (MRR) . Radial overcut (ROC)
Response surface methodology (RSM)
1 Introduction
Electrochemical machining (ECM) has tremendous poten-
tial on account of the versatility of its applications and it is
expected that it will be successfully and commercially
utilized in modern industries, although the effective
utilization of this machining technology will require the
application of a system approach to solve some of the
predominant machining problems, like stray current ma-
chining, generation of micro-spark during micro-machin-
ing. When ECM is used in the micron range, it is called
electrochemical micromachining (EMM) [1, 2]. The rela-
tionship between ECM process parameters and machining
accuracy criteria like overcut and conicity is established [3].
Machining voltage frequency, pulse on time and off time,
electrolyte concentration also play a predominant role in
generation of a micro-hole with high accuracy during the
electrochemical material removal process [4]. Moreover, it
is observed that during the electrochemical micromachining
process the increment in gap resistance due to various
causes, e.g. electrolyte heating, gas bubble generation,
sludge formation, etc., leads to the occurrence of micro-
sparks, causing larger radial overcut as well as a micro-
spark affected zone that results in poor quality of final
products [5]. Therefore, the optimal use of the EMM
process for achieving an enhanced production rate with
 Int J Adv Manuf Technol

improved profile accuracy demands proper control of

machining parameters through a suitable EMM setup.
Optimal quality of the workpiece in EMM can be generated
through combinational control of various process parame-
ters. The present paper, therefore, emphasises features of
the development of comprehensive mathematical models
for correlating the interactive and higher-order influences of
the various machining parameters, such as the pulse on/off
ratio, machining voltage, electrolyte concentration, voltage
frequency, tool frequency on the predominant machining
criteria, i.e. the metal removal rate and radial overcut, for
achieving controlled EMM. The investigation into the
influence of ECM process parameters on machining
performance criteria has been carried out through the devel-
opment of mathematical models based on response surface
methodology (RSM) [6], utilizing the relevant experimental
data as obtained through experimentation. Response surface
methodology (RSM) is also used in the present research
work for correlating the various machining parameters,
such as the pulse on/off ratio, machining voltage, electro- Fig. 1 Photographic view of mechanical machining unit
lyte concentration, voltage frequency, tool frequency on the
predominant electrochemical micromachining (EMM) cri-
teria, i.e. the metal removal rate and radial overcut. The micro tool and workpiece that may cause generation of
adequacy of the developed mathematical models has also microsparks, which in turn reduces machining accuracy.
been tested by the analysis of variance test. Piezoelectric transducer (PZT) was used for vibrating micro
tools [11], which enhance the end gap and improve the
circulation of electrolyte that result in reduction or
2 Experimental set up elimination of microsparks generation. To carry out the
experiments with vibrating micro tool, a micro tool
Considering the influence of predominant process char- vibration system was developed [12]. This developed
acteristics, a well-planned research program has been system consists of mainly two sub units, i.e. tool holder
considered for experimentation in the developed EMM unit and tool vibrator unit.
system [7, 8]. The developed system consists of various
sub-components, e.g. mechanical machining unit, micro
tool vibrating unit, electrical power and controlling system,
and controlled electrolyte flow system, etc. [9]. A very
small interelectrode gap (IEG) in the range of 10–15 μm, is
maintained during the EMM process to increase the
localization effect for producing a higher quality machined
product [10]. The developed EMM set up is capable of
maintaining required IEG during the EMM process.
Photographic view of mechanical machining unit of the
developed EMM setup is exhibited through Fig. 1.
Electrical power and controlling system is comprised of
the pulse generating unit, microprocessor and stepper motor
along with controlling units, exhibited in Fig. 2. The pulsed
generating unit is utilized to provide the required pulse
nature of power supply for the micromachining operation
that improves the accuracy and surface quality of the
machined job. Stepper motor is used to give the feed
motion to the micro tool and it is controlled by an Intel
8085 microprocessor. During this process, there may be a Fig. 2 Photographic view of power supply unit and microprocessor
possibility of striking reaction products in-between the control unit
Int J Adv Manuf Technol

3 Planning of the experimental design
The indigenous EMM experimental set has been designed
and developed successfully to analyze the influence of
predominant machining parameters, i.e. pulse on/off ratio,
machining voltage, electrolyte concentration, voltage fre-
quency and tool vibration frequency during EMM opera-
tion on the desired machining performance characteristic,
i.e. material removal rate and machining accuracy with
better surface quality of machined products. The experi-
mentation scheme was designed in such a way as to
explore the influence of the various predominant machin-
ing parameters, based on RSM with the help of MINITAB
software, in order not only to obtain the optimal scheme
for multi-variable experimentation, but also to perform
studies for exploring the interactive and higher-order
effects of the various parameters considered. The exper-
imental plan for studying the relationship between the
controlling parameters and the various machining criteria,
based on central composite half fraction second-order
rotatable design, is shown in Table 1. The original values
of the various levels for controlling process parameters in
this set of investigations are as shown in Table 2.
A stainless steel wire of diameter 335 μm was used as
the micro tool for the experimentation. The micro tool was
coated with a very thin layer of synthetic material. The
workpiece specimens were 15×10×0.15 mm bare copper
plates. The electrolyte used for experimentation was fresh
aqueous solution of sodium nitrate (NaNO3) with varying
electrolyte concentration because of its high conductivity
and non-passive characteristic. Variable rectangular DC
pulsed supply was used for experimentations. The material
removal rate (MRR) and accuracy in terms of radial overcut
was observed for various sets of experiments with different
combinations of process parameters based on response
surface methodology (RSM). Amplitude of micro-tool
vibration was typically chosen as 8 V-RMS for performing
all sets of experiments as at this vibration amplitude lesser
radial overcut could be achieved. The amplitudes were
measured by true RMS multimeter. So the values are in

Table 1 Plan for central com-

posite half fraction rotatable Expt. No. x1 x2 x3 x4 x5 MRR (g/min) ROC (mm)
second order design
1 −1 −1 −1 −1 1 0.69446 0.023000
2 1 −1 −1 −1 −1 0.49448 0.258750
3 −1 1 −1 −1 −1 1.08200 0.228864
4 1 1 −1 −1 1 0.86490 0.264320
5 −1 −1 1 −1 −1 0.63812 0.018500
6 1 −1 1 −1 1 0.70511 0.170000
7 −1 1 1 −1 1 1.01228 0.211288
8 1 1 1 −1 −1 0.90600 0.137955
9 −1 −1 −1 1 −1 0.66900 0.282500
10 1 −1 −1 1 1 0.67302 0.143611
11 −1 1 −1 1 1 0.87941 0.200830
12 1 1 −1 1 −1 0.72345 0.121140
13 −1 −1 1 1 1 0.76081 0.221786
14 1 −1 1 1 −1 0.62941 0.279210
15 −1 1 1 1 −1 1.12242 0.230510
16 1 1 1 1 1 1.05966 0.094000
17 −2 0 0 0 0 0.77195 0.107357
18 2 0 0 0 0 0.62808 0.168864
19 0 −2 0 0 0 0.50221 0.204290
20 0 2 0 0 0 1.12904 0.143198
21 0 0 −2 0 0 0.70914 0.235192
22 0 0 2 0 0 1.06508 0.218214
23 0 0 0 −2 0 0.81948 0.161389
24 0 0 0 2 0 0.91998 0.203190
25 0 0 0 0 −2 0.89469 0.180000
26 0 0 0 0 2 0.98655 0.112857
27 0 0 0 0 0 0.88242 0.130119
28 0 0 0 0 0 0.89597 0.106698
29 0 0 0 0 0 0.83790 0.110625
30 0 0 0 0 0 0.88869 0.117350
31 0 0 0 0 0 0.86993 0.101583
32 0 0 0 0 0 0.92481 0.106559
 Int J Adv Manuf Technol

Table 2 Original values of

machining parameters Parameters Symbols Levels

−2 −1 0 1 2

Pulse on/off ratio x1 0.5 1.0 1.5 2.0 2.5

Machining voltage (V) x2 2.5 3.0 3.5 4.0 4.5
Electrolyte concentration (g/l) x3 10 15 20 25 30
Voltage frequency (Hz) x4 35 40 45 50 55
Tool vibration frequency (Hz) x5 100 150 200 250 300

V-RMS unit. Machining accuracy was measured in terms of
radial overcut phenomena. Micro-hole inspection and
measurement were performed with the help of measuring
microscope (OLYMPUS, JAPAN) and the radial over cut of
the machined micro-holes was noted. The weight of test
pieces was measured before and after machining by using a
precision weighing machine (Mettler Toledo, Switzerland)
and machining time was noted with help of a stopwatch
(Baker, India) for calculating material removal rate. A
scanning electron microscope was also used to study the
effects of various predominant process parameters, i.e.
machining voltage pulse on/off ratio, machining voltage,
electrolyte concentration, voltage frequency and tool
vibration frequency. The condition of machined micro-
holes was observed through scanning electron micrographs
(SEM). A high frequency digital storage oscilloscope,
ScopeCorder, DL750 (YOKOGAWA, JAPAN) was utilized
for monitoring the state of pulsed power supply during
micromachining experiments.
4 Experimental analysis for the response surface
methodology (RSM) based modeling
The response surface methodology (RSM) is a useful tool
for finding the relationship between various process
parameters and the machining criteria of a machining
process so as to explore the effect of these parameters on
the responses criteria of the machining process. The
objective of the response surface methodology is to develop
the mathematical link between the responses and predom-
inant machining parameters. The general second order
polynomial response surface mathematical model can be
considered to evaluate the parametric influences on the
various machining criteria as follows:
X
n X
n X
Yu ¼ b o þ bi xiu þ bii x2iu þ bij xiu xju ð1Þ
i¼1 i¼1 i
j
where Yu represents the corresponding response, e.g. MRR
and ROC of the EMM process in the present research. The
code values of ith machining parameters for uth experiment
are represented by xiu. The values of n indicates the number
of machining parameters. The terms bi, bii and bij are the
second order regression co-efficient. The second term under
the summation sign of this polynomial equation attributes
to linear effects, whereas the third term of the above
equation corresponds to the higher order effects and lastly
the forth term of the equation includes the interactive
effects of the parameters.
In the present set of analyses, the voltage pulse on/off
ratio (x1), machining voltage (x2), electrolyte concentration
(x3), voltage frequency (x4), tool vibration frequency (x5)
were considered as controlling variables. Their effects on
material removal rate (MRR) and radial overcut (ROC) are
tested through a set of planned experiments based on
central composite second order half fraction rotatable
design. The experiment has been carried out according to
the designed experimental based on central composite half
fraction second order rotatable design as depicted in Table 1.

Table 3 ANOVA for MRR & ROC

Source of variation D.OF. Sum of square Mean sum of square F value P value

MRR ROC MRR ROC MRR ROC MRR ROC

Regression 20 0.884125 0.140773 0.044206 0.007039 0.000 0.000

First term 5 0.708576 0.013307 0.141715 0.002661 0.000 0.004
Square term 5 0.090748 0.030734 0.018150 0.006147 0.001 0.000
Interaction 10 0.084801 0.096733 0.008480 0.009673 0.008 0.000
Lack of fit 6 0.015210 0.003837 0.002535 0.000639 3.05 6.09
Experimental error 5 0.004153 0.000525 0.000831 0.000105
Total 31 0.903488 0.145135
Int J Adv Manuf Technol
The machining criteria, e.g. metal removal rate and radial
overcut has been observed for each experiments and the
results obtained through a series of experiments for various
sets of parametric combinations as planned have been
exhibited in Table 1.
4.1 Mathematical modeling of MRR
Based on Eq. (1), the effects of the above-mentioned
process variables on the magnitude of the MRR have been
evaluated by computing the values of the different
constants of Eq. (1) using MINITAB software and utilising
the relevant data from Table 1. The mathematical relation-
ship for correlating the MRR (Yu) and the considered
process variables is obtained as follows:
MRRðYMRR Þ ¼ 1:78917 þ 0:111858x1 þ 1:36263x2
 0:0864044x3 þ 0:0231122x4
 0:00139639x5  0:201666x1 2
 0:0860582x2 2  0:000145752x3 2
 0:000319532x4 2 þ 3:893684
 1006 x5 2  0:0704326x1 x2
þ 0:00838936x1 x3 þ 0:00275664x1 x4
þ 0:00178484x1 x5 þ 0:00870264x2 x3
 0:00700764x2 x4  0:00105004x2 x5
þ 0:00125437x3 x4
þ 0:0000247626x3 x5
þ 0:0000181174x4 x5 :::: ð2Þ
The adequacy of the above model has also been tested
through the analysis of variance. The results of the analysis
justifying the closeness of fit of the mathematical model
have been enumerated, as shown in Table 3. It is concluded
that the devolved model given by Eq. (2) is quite adequate
at 90% confidence level with degree of freedom 6 and 5
and demonstrate the independent and quadratic effects of
the different machining parameters on the MRR.
4.2 Mathematical modeling of ROC
A model based on Eq. (1) has been developed to correlate
the interaction and higher-order effects of the previously-
mentioned process parameters on the ROC, utilizing the
relevant experimental data as observed (Table 2) during the
course of machining for such purposes as varying paramet-
ric combinations. The mathematical relationship thus
obtains for analyzing the influences of the various dominant
machining parameters on the ROC is given by:
ROC ðYROC Þ ¼ 1:08149 þ 1:21039x1 þ 0:448639x2
 0:0821333x3 þ 0:0247783x4
 0:00258589x5 þ 0:0198541x1 2
þ 0:0554876x2 2 þ 0:00108447x3 2
þ 0:000640329x4 þ 2:817205
 1006 x5 2  0:139966x1 x2
 0:00133867x1 x3  0:0161759x1 x4
 5:41335  1005 x1 x5
 0:00307591x2 x3  0:0163201x2 x4
þ 0:000831331x2 x5
þ 0:000786541x3 x4
þ 0:0000725981x3 x5  6:94181
 1005 x4 x5 :::: ð3Þ
The adequacy of the above model has also been tested
through the analysis of variance. The results of the analysis
justifying the closeness of fit of the mathematical model
have been enumerated, as shown in Table 3. It is concluded
that the evolved model given by Eq. (3) is quite adequate at
97.5% confidence level with degree of freedom 6 and 5 and
demonstrate the independent and quadratic effects of the
different machining parameters on the OC.
5 Analysis of results based on the developed
mathematical models
5.1 Influence of machining voltage and electrolyte
concentration on material removal rate (MRR)
Figure 3 exhibits the influence of machining voltage and
electrolyte concentration on material removal rate (MRR).
Figure shows that material removal rate (MRR) increases
with an increase of machining voltage for all level
electrolyte concentration at particular micromachining
parametric combination, i.e. pulse on/off ratio of 1.5,
voltage frequency of 45 Hz and tool vibration frequency
of 200 Hz. Machining current increases with an increase in
machining voltage. According to the Faradays’ Law
material removal rate is proportional to the machining
current. However, in a very small inter-electrode gap less
than 25 μm needed for electrochemical micromachining
(EMM) MRR does not vary linearly as polarization voltage

Fig. 3 Influence of machining
voltage and electrolyte concen-
tration on (MRR)
is not constant. Increment rate of MRR at lower machining
voltage range, i.e. from 2.5 V to 3.5 V, is higher compare to
the higher machining voltage range, i.e. from 3.5 V to
4.5 V. These trends are the consequences of a larger
increment of dissolution efficiency at lower range of
machining voltage. The response surface graph also shows
the influence of electrolyte concentration on MRR at the
same preset values of pulse on/off ratio, voltage frequency
and tool vibration frequency under varying machining
voltage. With an increase in electrolyte concentration,
material removal rate (MRR) also increases for every
machining voltage. At higher electrolyte concentration, the
larger number ions associated with the machining pro-
cesses, increases the machining current and thus results in
higher MRR.
Fig. 4 Influence of pulse on/off
ratio and voltage frequency on
MRR
Int J Adv Manuf Technol
5.2 Influence of pulse on/off ratio and voltage frequency
on material removal rate (MRR)
Figure 4 illustrates the influence of pulse on/off ratio and
voltage frequency on MRR. It is clear from the graph that at
lower value of voltage frequency, i.e. at 35 Hz, material
removal rate (MRR) initially increases with pulse on/off
ratio and after achieving the maximum value, MRR starts
decreasing with further increase in pulse on/off ratio at a
preset machining parametric combination, i.e. machining
voltage of 3.5 V, electrolyte concentration of 20 g/l and tool
vibration frequency of 200 Hz. Off time decreases with an
increase in on/off ratio for a particular voltage frequency as
pulsed machining voltage cycle time is fixed. During on
time material removal takes place and during off time
Int J Adv Manuf Technol
machined product is flushed away from the machining
zone, so that fresh electrolyte comes into the interelectrode
gap causing proper dissolution of workpiece material. With
increase in on/off ratio, on time increases and simulta-
neously off time decreases. Initially dissolution of material
increases with increases in on/off ratio due to the more
machining time. With further increases in on/off time ratio,
MRR decreases in smaller span of off time and the entire
machined product can not be removed completely from the
machining zone causing improper dissolution of workpiece
material.
5.3 Influence of machining voltage and tool vibration
on material removal rate (MRR)
Response surface plot of MRR with respect to machining
voltage and tool vibration frequency is shown through
Fig. 5. The influence of machining voltage on MRR is
already explained. The figure also illustrates that for a
preset machining voltage, MRR increases with an increase
in tool vibration frequency. It is clear from the graph the
material removal rate (MRR) increases with tool vibration
frequency at every value of machining voltage keeping the
other machining parameters at preset values. For every
cycle of tool vibration, once the tool maintains a preset
interelctrode gap during the machining the tool is with-
drawn, making the gap between job and micro-tool more
for flushing away the sludge material completely. At lower
tool vibration frequency the number of withdrawal of tool
and flushing away the sludge material from the machining
zone are fewer, which causes improper dissolution of
workpiece material which results in lower material removal
rate (MRR). When the frequency of tool vibration
increases, material removal rate (MRR) increases in
Fig. 5 Influence of machining
voltage and tool vibration fre-
quency on MRR
consequence of proper dissolution of workpiece material
due to the greater amount of sludge material flushing from
the machining zone.
5.4 Influence of machining voltage and electrolyte
concentration on radial overcut (ROC)
Figure 6 shows the influence of machining voltage and
electrolyte concentration on ROC. At 10 g/l of electrolyte
concentration, ROC decreases with an increase in machin-
ing voltage in the machining voltage zone from 2.5 V to
3 V and then ROC increases with further increases in
machining voltage range from 3 V to 4.5 V. Machining
voltage of 2.5 V with 10 g/l electrolyte concentration zone,
linear material removal rate is less than tool feed rate,
which causes the microspark due to the touching of the tool
to the workpiece. With an increase in machining voltage the
chance of occurrence of microspark reduces and hence
reduces the radial overcut in this machining voltage zone
from 2.5 V to 3 V. In the higher voltage range electro-
chemical reaction generates hydrogen gas bubbles and
those bubbles break down resulting in the occurrence of
microsparks. Localization effect diminishes as stray ma-
chining has significant effect in the higher machining
voltage range, i.e. 3.5 V to 4.5 V. So, in this machining
voltage range ROC increases with machining voltage. This
sparking causes uncontrolled material removal from the
larger area of the workpiece, which in turn produces larger
side gap. The nature of variations of ROC with machining
voltage for different electrolyte concentrations are almost
the same, i.e. initially decreases and than increases with
increases in machining voltage. Keeping machining voltage
at 2.5 V, ROC decreases with increases electrolyte concen-
tration up to 20 g/l. In the zone of electrolyte concentration

Fig. 6 Influence of machining
voltage and electrolyte concen-
tration on ROC
from 15 g/l to 20 g/l, ROC decreases with increase in
electrolyte concentration as the chance of occurrence of
microspark is reduced. Further increase in electrolyte
concentration ROC increases as in the higher electrolyte
concentration range electrochemical reaction generates
hydrogen gas bubbles and those bubbles breaks down
resulting in the occurrence of microsparks. Localization of
current flux flow decreases with an increase in electrolyte
concentration. Stray current flow increases in the machining
zone due to the poor localization effect, in turn affecting the
increased material removal from the larger area of the
workpiece, which causes an increase in ROC.
5.5 Influence of pulse on/off ratio and tool vibration
frequency on radial overcut (ROC)
Figure 7 depicts the influence of pulse on/off ratio and tool
vibration frequency on ROC during machining with
Fig. 7 Influence of pulse on/off
ratio and tool vibration frequen-
cy on ROC
Int J Adv Manuf Technol
machining voltage of 3.5 V, electrolyte concentration of
20 g/l and voltage frequency of 45 Hz. Machining with
100 Hz of tool vibration frequency, ROC increases with an
increase in on/off ratio. Off time, during which machined
product flushed from the machining zone, decreases with
on/of ratio, which increases the chance of microsparking
and hence increases the ROC. Moreover, localization effect
diminishes with an increase in pulse on/off ratio as on time
increases. However, at higher zone of tool vibration
frequency, from 100 Hz to 200 Hz, ROC initially increases
with an increase in pulse on/off ratio; attain the minimum
value at 1.5, and further increase in on/off ratio ROC starts
increasing. At 0.5 on/off ratio, tool feed rate is more than
the linear material removal rate and hence touches the tool
to the workpiece causing generation of microspark that
results in larger ROC. In the zone of 0.5 to 1.5 with a
higher tool vibration frequency zone, i.e. from 200 Hz to
300 Hz, linear material removal rate increases and become
Int J Adv Manuf Technol
equal to tool feed rate at 1.5 of pulse on/off ratio. Further
with an increase in on/off ratio, off time decreases results in
improper flushing of machined product from the machining
zone and the chance of generation of microsparks increases,
which results in larger ROC. The figure also depicts that at
any pulse on/off ratio with an increase in tool vibration
frequency, ROC decreases. At higher frequency of tool
vibration, the chance of making a larger gap between
micro-tool and workpiece is more, which helps in evacu-
ation of sludge material from the machining zone which
results in reduction of the chance of generating a micro-
spark and less ROC is the subsequent result. Tool vibration
propagates pressure waves in the electrolyte in the
machining zone, which also helps in flushing away the
sludge and gas bubble generated during the machining
process leads to less ROC. The evacuation of sludge
material by pressure wave is more significant at higher
tool vibration frequency.
5.6 Influence of machining voltage frequency and tool
vibration frequency on radial overcut (ROC)
Figure 8 exhibits the response surface graph of ROC with
respect to voltage frequency and tool vibration frequency.
The figure shows that at 100 Hz, tool vibration frequency
with increases in voltage frequency cause radial overcut
increases. This can be explained as the number of on and
off time increases but time span of both the times decrease.
During the off time machined product is flushed away from
the machining zone. With an increase in voltage frequency,
off time decreases causing improper removal of sludge
material from the machining zone which results in micro-
spark. These generations of microsparks in the machining
zone, result in uncontrolled material removal from the
workpiece and produced larger micro-hole, or in other word
Fig. 8 Influence of machining
voltage frequency and tool
vibration on ROC
larger ROC. At 35 Hz of machining voltage frequency,
ROC increases with an increase in tool frequency. Though,
at 35 Hz voltage frequency span of on time is more, but
effective machining time decreases as the number of
withdrawal of tool from the machining zone increases with
an increase in tool frequency. Hence, the linear material
removal rate from the workpiece becomes less than tool
feed rate and the chance of touching the tool to workpiece,
which generates the microspark increases and larger ROC is
the final consequence. Therefore, at 35 Hz voltage
frequency ROC increases with tool vibration. At tool
frequency of 200 Hz, ROC initially decreases upto 45 Hz
and than increases with further increase in voltage
frequency. At lower voltage frequency of 35 Hz on time
and off time both are more. Material removal rate as well as
generation of machined product is more due to the larger on
time. Though off time is also larger at 35 Hz voltage
frequency it is not sufficient to flush away the material from
the machining zone completely. This phenomena initiates
the microspark, and causes larger ROC at 35 Hz voltage
frequency with 200 Hz tool frequency. With an increase in
voltage frequency up to 50 Hz on time decreases and hence
the generation of machined products decreases, and chances
of flushing away these products from the machining zone
completely increases and lessens the chance of microspark
propagation and smaller ROC is the ultimate consequence.
At 300 Hz, frequency of tool vibration, same nature of
variation of ROC has been observed. The minimum ROC
achieved at 53 Hz voltage frequency.
6 Analysis for optimality search
Based on the developed second-order response surface
equations, i.e. Eq. (2) and Eq. (3) for correlating the various

Table 4 Optimum values for
process parameters Parameters
Pulse on/off ratio
Machining voltage (V)
Electrolyte concentration (g/l)
Voltage frequency (Hz)
Tool vibration frequency (Hz)
process variable effects with the MRR and ROC optimality
searches can be obtained. This is carried out to determine
the optimal combination of the machining parameters and
their combine effects on the desired response criteria. The
optimality search model for the various process variable
conditions for maximizing the MRR, minimizing the ROC
value of various machined workpieces was formulated
based on the methodology as described. The optimum level
of machining performance criteria can be achieved at a
particular parametric combination, i.e. 3 V of machining
voltage, 1.0 of pulse on/off ratio, 42.118 Hz of voltage
frequency, 15 g/l of electrolyte concentration, 300 Hz of
tool vibration frequency. Optimum values of machining
process parameters for different micromachining criteria are
also shown on Table 4. Machining with optimum paramet-
ric combination, micro-hole produced with very smaller
radial overcut, around 20 μm with material removal rate
(MRR) as high as 0.700 g/min.
Condition of a micro-hole machined under parametric
combination of pulse on/off ratio of 1.5, machining voltage
of 4.5 V, electrolyte concentration of 20 g/l, voltage
frequency of 45 Hz and tool vibration frequency of
200 Hz, which gives maximum MRR, is depicted through
Fig. 9 SEM micrograph and voltage graph: Pulse on/off ratio 1.5, Machining voltage 4.5 V, Electrolyte concentration 20 g/l, Voltage frequency
45 Hz, Tool vibration frequency 200 Hz
Int J Adv Manuf Technol
Optimum values MRR (g/min) ROC (μm)
1.0 0.70374 g/min 20 μm
3.0 V
15 g/l
42.118 Hz
300 Hz
SEM micrograph in Fig. 9. At this machining parametric
combination MRR as well as larger overcut is observed at
this higher machining voltage and higher electrolyte
concentration causes more stray current machining. How-
ever, the chance of microspark initiation is almost elimi-
nated due to higher linear material removal rate than
micro-tool feed rate. No distortion in the voltage pulse
pattern is observed in voltage graph on the Fig. 9, which
corroborates the absence of microsparks during machining
under this parametric combination. Figure 10 shows the
SEM micrograph of a micro-hole machined under the
parametric combination of 1.0 pulse on/off ratio, 3.0 V,
machining voltage, 25 g/l of electrolyte concentration,
voltage frequency of 40 Hz and tool vibration frequency
of 150 Hz where minimum radial overcut is observed. The
nature of pulse voltage pattern during machining with the
same parametric combination is also exhibited through
voltage graph in the same figure. The distortion of the
voltage pattern observed on the graph is due to the
occurrence of few microsparks. SEM micrograph in
Fig. 11 exhibits the condition of a micro-hole machined at
a parametric combination of 1, pulse on/off ratio, 3.0 V,
machining voltage, electrolyte concentration of 15 g/l,
Int J Adv Manuf Technol

Fig. 10 SEM micrograph and voltage graph: Pulse on/off ratio, 1.0; Machining voltage, 3.0 V; Electrolyte concentration, 25 g/l; Voltage
frequency, 40 Hz; Tool vibration frequency, 150 Hz

voltage frequency of 50 Hz and tool vibration frequency of
250 Hz, which gives values close to the optimum level of
MRR and ROC obtained from the developed models.
Microspark occurrence is not completely eliminated and
hence small distortion in the voltage pulse pattern is
observed on voltage graph in Fig. 11. The surface quality
of the machined micro-hole is also better than the previous
one, as shown in SEM micrograph.
7 Conclusions
The experimental analysis highlights that the electrochem-
ical micromachining criteria like MRR, ROC in EMM are
greatly influenced by the various predominant machining
parameters considered in the present study. Response
surface methodology used in the present research work
has proved its adequacy to be an effective tool for analysis
of the EMM process. Mathematical models for correlating
MRR and ROC with predominant process parameters have
been obtained separately. The influence of different process
parameters on machining performance criteria are exhibited
though response surface plots. It is clear from the response
surface plot of MRR, the MRR increases with an increase
in any of the machining parameters except pulse on/off
ratio. However, at higher level of machining parameters,
except tool vibration frequency, gives higher ROC as
shown on the ROC response surface plots. Voltage pulse

Fig. 11 SEM micrograph and voltage graph: Pulse on/off ratio, 1.0; Machining voltage, 2.5 V; Electrolyte concentration, 15 g/l; Voltage
frequency, 50 Hz; Tool vibration frequency, 250 Hz

nature during machining with microsparking is shown
through different voltage graphs captured with a digital
storage oscilloscope. It is evident from the voltage graph
that though microspark occurs during machining, mostly at
lower electrolyte concentration, radial overcut diminishes
drastically due to lower stray current machining. This is
because at lower electrolyte concentration, stray current
machining has more significant effect than micro-sparking
on radial overcut. Considering MRR and ROC simulta-
neously optimum values of predominant process parameters
have been obtained as; pulse on/off ratio, 1.0, machining
voltage, 3 V, electrolyte concentration, 15 g/l, voltage
frequency of 42.118 Hz and tool vibration frequency as
300 Hz. Condition of machined micro-holes is depicted
though the different SEM micrographs.
Therefore, it is evident that the various quantitative
modellings, based on response surface methodology,
experimental analyses and the test results as obtained
through the present research will be quite useful for
analyzing the influence of the various process parameters
for achieving suitable control over the electrochemical
micromachining performance criteria. These models will
also be very helpful to find out the exact parametric
combination for a particular desirable accuracy with a
particular machining rate. The present experimental find-
ings will be useful for both the design and manufacturing
engineers to assess the necessary information about
influence of predominant machining parameters on electro-
chemical micromachining performance. Microsparks occur
during micromachining operation causing uncontrolled
material removal, resulting in the generation of improper
shape and low accuracy. The shortcoming associated with
the generation of microspark, which is uncontrollable and
detrimental to the workpiece shape generation as well as to
the micro-tool, during machining can be minimized; but
this should be eliminated to achieve a better shape and
size of the final machined component with high accuracy.
Material removed through stray current machining and
micro sparking can also be minimized, but could not be
eliminated completely through selection of the proper
machining parametric combination by utilizing the developed
Int J Adv Manuf Technol
models of this present investigation. Further research
activities on EMM will open up many challenging possibil-
ities such as elimination of microspark generation as well as
stray current machining during EMM operation to achieve a
better shape and size of the final machined component with
high accuracy at higher machining rate.
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