The influence of Sodium Nitrate electrolyte on Aluminium scrapped wheel in the ECM process

Electrochemical Machining (ECM) stands out as a non-traditional method for intricately shaping materials. It operates on the principles of Faraday’s laws of electrolysis, where the weight of the substance generated during electrolysis correlates directly with the current flow, process duration, and equivalent weight of the deposited material. This research specifically investigates assessing the impact of Sodium Nitrate (NaNO3) electrolyte on machining Aluminium scrapped wheel. Three ECM input parameters voltage, electrolyte concentration, and duty cycle are varied across different levels. The study scrutinizes machining outputs, particularly Material Removal Rate (MRR) and overcut (OC), employing the Taguchi design methodology. Optimal process factors are presumed through SN ratio analysis and ANOVA is utilized to analyze the contribution of each parameter to the output characteristics. The results of the study suggest that MRR is improved, and an optimal configuration consists of 10 V voltage, 90% duty cycle, and 25 g/l electrolyte concentration. to minimize OC, 12 V voltage, 80% duty cycle, and 25 g/l electrolyte concentration are recommended.