The optimal parameters in a magnetically assisted finishing system using Taguchi's method

An intelligent design system was created that efficiently uses magnetic force to assist in the discharge of dregs from the electrode gap during the electrochemical step of a surface finishing process. In this electrochemical finishing experiment, the author used an electrode mated to the shape of the workpiece and supplied with continuous or pulsed direct current. The study used Taguchi's Method to analyze the combination of optimal parameters. The experimental parameters include four factors at three levels for the evaluation of surface roughness after the magnetically assisted electrochemical finishing process. These four factors are voltage, magnetic field strength, the distance between the two magnets and the electrode rotation speed. For this design a higher rotation speed of the electrode produced a better finish. A higher voltage with magnetic assistance can alleviate the difficulties of dregs discharge and also reduce the finishing time. Smaller distances between the two magnets, or a larger magnetic field intensity provides more magnetic force, improved discharge and results in a better finish. The average effect of magnetic assistance was greater than that of pulsed current and there is no need to prolong machining time to compensate for off-time.