Modelling and optimizing surface roughness and MRR in electropolishing of AISI 4340 low alloy steel in eco-friendly NaCl based electrolyte using RSM

Abstract Electropolishing (EP) is a reliable post-processing method of the drilled metals for achieving high-quality surface finish with an appropriate material removal rate. This process has many applications due to its advantages such as improving quality by removing peaks on micro-scale. The aim most attempts this setting up optimum parameters obtain maximum Material Removal Rate (MRR) minimum roughness. In present wo k, electropolishing AISI 4340 low alloy steel immersed in eco-friendly NaCl solution been studied numerically and experimentally. So, primarily simulation model was developed EP cylinder parts COMSOL Multiphysics which validated experimental approaches. results revealed that numerical would be convenient EP. experiments were performed using Response Surface Methodology (RSM) evaluate effect input variables responses. effects electrolyte temperature, current intensity, primary gap investigated outputs MRR roughness at five levels. Based results, temperature intensity more effective outputs. Results ANOVA regression analysis approach increasing increases correspondingly declines reverse MRR. Finally, performing multi-objective optimization Derringer’s desirability approach, optimized.