Optimization of the electrochemical machining parameters in drilling of AA6O6I-TIB₂ in-situ composites produced by K₂TiF₆-KBF₄ reaction system

Utilization of un conventional machining is increased exponentially due to its specific advantages like good machinabilty on the ceramic materials, ability to make complex profiles and supreme surface finish. Among the various un conventional machining, the electro chemical machining has unique identity including reasonably higher machining rate along with thermal and mechanical stress free machined surface. In-situ composites are made by reinforcing the micro size reinforcement by chemical reaction. The mechanical properties of these composites superior due its good interfacial bonding and smaller grain size of the matrix. The current paper deals the optimization of the electrochemical drilling parameters in machining of AA6061-5% T1B₂ in-situ composites produced by K₂TiF₆- KBF₄ reaction system. Current, concentration of the electrolyte and applied voltage are preferred as matrix whereas removal rate of the material and taper of the electrochemically drilled hole is identified to assess the machinbility. L₂₇ orthogonal layout is followed for experimental work and Taguchi method deployed for optimization. Analysis of result and variance indicates that the preferred responses have significant influence on the responses.