Amirkabir University of Technology Amirkabir Journal of Mechanical Engineering 2008-6032 54 6 2022 08 23 Experimental Investigation of Electrochemical Finishing Process Using Box-Behnken Design in Response Surface Methodology Experimental Investigation of Electrochemical Finishing Process Using Box-Behnken Design in Response Surface Methodology 1409 1422 4802 10.22060/mej.2022.20708.7299 FA Bahman Nemati دانشگاه زنجان گروه مهندسی مکانیک Rasoul Moharrami گروه مهندسی مکانیک، دانشکده مهندسی، دانشگاه زنجان، Mohammad Mostafa Mohammadi زنجان-مهندسی- گروه مهندسی مکانیک Journal Article 2021 10 25 Electrochemical polishing is a nontraditional finishing process by which the surface roughness of the metallic workpiece is reduced due to anodic dissolution. In this process, an electrochemical cell is formed using the workpiece as the anode, a tool as the cathode, and a power supply.  Different parameters like inter electrode gap, the chemical composition of the electrolyte, and its temperature along with the electric potential affect the finishing performance. The important performance parameters are surface roughness, material removal rate, and the dimensional tolerance of the workpiece. In this article, the effect of inter electrode gap, cathode geometry, tool feed rate, and electric potential on the process outputs are evaluated experimentally. Due to the high number of input and output variables and possible interactions between the input variables, Box-Behnken design in response surface methodology is selected for designing the experiments. The experimental models are evaluated by analysis of variance. Using the response surface methodology, the effect of input parameters on process outputs and the possible interactions between the input variables are extracted. Also, multi-objective optimization is performed for determining the input variables which are adequate for maximizing the material removal rate along with achieving a predetermined amount for surface smoothness and geometric tolerance. Electrochemical polishing is a nontraditional finishing process by which the surface roughness of the metallic workpiece is reduced due to anodic dissolution. In this process, an electrochemical cell is formed using the workpiece as the anode, a tool as the cathode, and a power supply.  Different parameters like inter electrode gap, the chemical composition of the electrolyte, and its temperature along with the electric potential affect the finishing performance. The important performance parameters are surface roughness, material removal rate, and the dimensional tolerance of the workpiece. In this article, the effect of inter electrode gap, cathode geometry, tool feed rate, and electric potential on the process outputs are evaluated experimentally. Due to the high number of input and output variables and possible interactions between the input variables, Box-Behnken design in response surface methodology is selected for designing the experiments. The experimental models are evaluated by analysis of variance. Using the response surface methodology, the effect of input parameters on process outputs and the possible interactions between the input variables are extracted. Also, multi-objective optimization is performed for determining the input variables which are adequate for maximizing the material removal rate along with achieving a predetermined amount for surface smoothness and geometric tolerance. https://mej.aut.ac.ir/article_4802_137bdd55f159c4f5556391f53e608f2e.pdf