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In this study, electrochemical spark machining (ECSM) was utilized to create micro-holes in maraging steel. This study considered various input factors, such as the voltage (V), duty factor (D), and electrolyte concentrations (C). The machining quality was evaluated using material removal rate (MRR) and surface roughness (SR). To optimise the process, tests were carried out utilising Response Surface Methodology (RSM) with a Box-Behnken design. In addition, multi-objective optimization was performed. The results show that voltage has the greatest influence on both MRR and SR, followed by duty cycle and electrolyte concentration. A minimal surface roughness of 0.689 µm and a maximum material removal rate of 1.366 mg/min were obtained. The best machining settings for maximizing MRR and minimizing SR were found to be 37 V, 18% electrolyte concentration, and 25% duty cycle.

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Investigation and Optimization of Electrochemical-Assisted Spark Machining for Maraging Steel

  • 会议论文

  • 发表日期：

    2026年

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  • Nitesh Kumar,
  • Harish Bishwakarma,
  • Pankaj Kumar,
  • Niladri Mandal

摘要

In this study, electrochemical spark machining (ECSM) was utilized to create micro-holes in maraging steel. This study considered various input factors, such as the voltage (V), duty factor (D), and electrolyte concentrations (C). The machining quality was evaluated using material removal rate (MRR) and surface roughness (SR). To optimise the process, tests were carried out utilising Response Surface Methodology (RSM) with a Box-Behnken design. In addition, multi-objective optimization was performed. The results show that voltage has the greatest influence on both MRR and SR, followed by duty cycle and electrolyte concentration. A minimal surface roughness of 0.689 µm and a maximum material removal rate of 1.366 mg/min were obtained. The best machining settings for maximizing MRR and minimizing SR were found to be 37 V, 18% electrolyte concentration, and 25% duty cycle.