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Electrochemical machining is one of the widely used non-conventional machining processes to machine co mplex and difficult shapes for electrically conducting ma terials, such as super alloys, Ti-alloys, alloy ste el, tool steel and stainless steel. Use of optimal ECM process condit ions can significantly reduce the ECM operating, to oling, and maintenance cost and can produce components with hi g er accuracy. This paper studies the effect of pro cess parameters on surface roughness (Ra) and material r moval rate (MRR), and the optimization of process conditions in ECM. Experiments were conducted based on Taguchi’s L9 orthogonal array (OA) with three process paramet ers viz. current, electrolyte concentration, and inter-elect rode gap. Signal-to-noise (S/N), the analysis of va riance (ANOVA) was employed to find the optimal levels and to anal yze the effect of electrochemical machining paramet ers on Ra and MRR. The surface roughness of the workpiece was dec reased with the increase in current values and elec tro yte concentration while causing an increase in material removal rate. The ability of the independent values to predict th e dependent values (R 2) were 87.5% and 96.3% for mean surface roughness and mate rial removal rate, respectively . Keyword: ECM, Carbon, MRR, , Ra, Taguchi Method.

Prediction of Surface Roughness and Material Removal Rate in Electrochemical Machining Using Taguchi Method