modeling and multi-objective optimization of low-frequency vibration-assisted chemical machining using central composite design in response surface methodology

Increasing the etching rate is one of the main optimization targets in the chemical machining (cm). traditionally, this target is fulfilled by some costly techniques like selecting stronger etchants and increasing the etchant concentration. also, other methods like increasing the etchant temperature and stirring the etchants by agitators are employed for increasing the etching rate. one of the advantages of these methods is reduction of the consumption of acidic etchants which results in the cost reduction and making an eco-friendley process. in this article, a systematic experimental study is performed on vibration-assisted cm of copper. in this technique, the workpiece vibrates in the etchant during the cm. for evaluating the performance of machining, effects of amplitude and frequency of vibrations, along with the temperature and concentration of acidic etchant, on material removal rate, surface roughness and machining undercut are studied experimentally. the experiments are designed by central composite design (ccd) in response surface methodology (rsm). also, multi-objective optimization is performed by defining a desirability function. the optimal vibro-assisted process parameters are temperature 60 ̊c, etchant concentration 600 g/l, vibration frequency 25 hz, and vibration amplitude 1.5 mm, to get optimal outputs on the desired parameters.