Optimization of Performance Parameters for Material Removal Rate in Side Flushing Form of Die Sink EDM

Abstract

In the present scenario, electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult to machine by conventional machining processes. EDM researchers have explored a number of ways to improve the efficiency including some unique experimental concepts. The operating performance measures of side flushing type of electrical discharge machining process on EN-31 die steel using copper electrode are being optimized according to its individual machining parameter, i.e., Material Removal Rate (MRR). An L27 orthogonal array of Taguchi methodology has been used to identify the effect of process input factors (viz., voltage, current, spark gap, pulse on time, duty cycle and flushing pressure) on material removal rate. Hence, the quality characteristic for MRR is set to higher-the-better to attain the optimum dimensional precision. Using Taguchi’s parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency and dielectric flow. The result had shown that significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency and dielectric flow. The results are further verified by conducting confirmation experiments.

Keywords: EDM, side flushing, optimization, Taguchi methodology, raw, S/N