Modelling of micro-electrochemical machining parameters used for machining of holes on copper plate

The electrochemical machining is a non-conventional machining process based on the electrolysis principle. It is used to machine various features on conducting engineering materials with the required accuracy and precision. So an attempt has been made to machine micro-holes on a 300 μm thick copper plate as an anode and a hollow stainless steel tool electrode of 250 μm diameter as the cathode. The machining operation is performed on the in-house developed micro-ECM experimental setup with controlled machining parameters voltage, concentration, and duty factor varied in three levels. A full factorial experimental plan is used to study the output responses material removal rate (MRR), radial overcut (ROC), circularity, and taper angle (TA). Later an adaptive neuro-fuzzy inference system (ANFIS) model has been developed and shown the effectiveness of the developed model in the paper. The Sugeno fuzzy model has been used in ANFIS to generate the fuzzy rules required for the model. Out of 27 experiments, 22 machining data are used for training the model, and the remaining 5 machining data are used for testing the developed model. The average error observed between the ANFIS predicted values and experimental values of MRR is 12.56%, circularity is 43.09%, ROC is 13%, and TA is 27.53%, respectively.