In this research, the authors explore the fabrication process of a hybrid composite AA5052/TiB₂/B₄C and investigate the influence of various electrochemical machining (ECM) parameters on the material removal rate (MRR). The study employs the Taguchi L16 orthogonal array for experimentation and employs Minitab-17 software to optimize MRR and determine the individual contribution of each parameter. The results are then analyzed using ANOVA (Analysis of variance) to identify the significant factors affecting MRR, which are found to be the feed rate of electrode (FR), voltage (VE), and electrolyte concentration (EC). The relationship between these parameters is illustrated using regression analysis and interaction plots. This research provides valuable insights into the optimal process parameters required to achieve the desired MRR in ECM of aluminum hybrid composite materials.

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