Proper selection of manufacturing conditions is one of the most important aspects in
the die sinking Electrochemical Machining process, as these conditions determine important
characteristics such as Material Removal Rate and Surface Roughness. The material used in the
study was LM25Al/10%SiCp composite. Experiments have been carried out to establish an
empirical relationship between process parameters and responses in ECM process using
Response Surface Methodology. The developed empirical relationships predict the machining
conditions within the experimental domain. Analysis of variance (ANOVA) is employed to
indicate the level of significance of machining parameters. The contour plots are generated to
study the effect of process parameters as well as their interactions. MRR is influenced by applied
voltage and tool feed rather than other parameters. Electrolyte concentration has most significant
factor on Ra rather than other parameters.