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<p>The electropolishing process is typically employed to decrease the microscopic surface roughness and enhance the surface brightness of metals. The macroscopic surface roughness is generally reduced by mechanical or chemical–mechanical finishing processes. This paper evaluates the smoothing capability of the electropolishing process in reducing the macroscopic surface roughness of stainless steel AISI 304 using experimental design strategies. The experimental study was conducted in two steps to reduce the number of experiments. In the first step, the screening experiments were performed using a Plackett–Burman design, and the most influencing process variables were identified. In the second step, by using the response surface methodology, an empirical model was developed that relates the smoothing capability of the electropolishing to the selected process variables. The analysis of variance was used to verify the adequacy of the empirical model. The results indicate that process time, electrolyte temperature,&#xa0;and electrolyte composition have the highest contribution to the smoothing capability of electropolishing, respectively. The optimum electropolishing conditions for maximizing the smoothing capability were: an electrolyte composition of 10% glycerol, 80% phosphoric acid to sulfuric acid, a temperature of 77 °C, and an electropolishing time of 13 minutes.</p>

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Combined Plackett–Burman Response Surface Methodology Technique for Sensitivity Analysis and Optimization of 304SS Electropolishing Process

  • 期刊论文

  • 发表日期：

    2025年5月9日

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  • Elnaz Besharati Givi,
  • Mohammad Mostafa Mohammadi

摘要

The electropolishing process is typically employed to decrease the microscopic surface roughness and enhance the surface brightness of metals. The macroscopic surface roughness is generally reduced by mechanical or chemical–mechanical finishing processes. This paper evaluates the smoothing capability of the electropolishing process in reducing the macroscopic surface roughness of stainless steel AISI 304 using experimental design strategies. The experimental study was conducted in two steps to reduce the number of experiments. In the first step, the screening experiments were performed using a Plackett–Burman design, and the most influencing process variables were identified. In the second step, by using the response surface methodology, an empirical model was developed that relates the smoothing capability of the electropolishing to the selected process variables. The analysis of variance was used to verify the adequacy of the empirical model. The results indicate that process time, electrolyte temperature, and electrolyte composition have the highest contribution to the smoothing capability of electropolishing, respectively. The optimum electropolishing conditions for maximizing the smoothing capability were: an electrolyte composition of 10% glycerol, 80% phosphoric acid to sulfuric acid, a temperature of 77 °C, and an electropolishing time of 13 minutes.