Abstract
Electrode material inelectro discharge machining EDM process plays an important role in terms of material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). The purpose of this research is to investigate the capability of different electrode materials: copper, aluminum and graphite in EDM of AISI 304 stainless steel as a work piece. The research focuses on three current settings: 2.5A, 4.5A and 6.5A using kerosene as dielectric fluid. The experiment is planned and analyzed using full factorial of the experimental design using response surface methodology (RSM). two outputs have been investigated: MRR and EWR. The results indicated that the responses increased with the increase in current. Finally the desirability function method have been used to determine the optimum values. The resulat show that the maximum MRR and  the minimum EWR were achieved by using graphite electrode at current 6.5A.
Highlights
Electro-discharge machining (EDM) is a thermoelectric process during which the heat energy of the spark produced between the electrodes is used to erode materials from the electrodes [1]
The performance of the EDM process is measured by different outputs such as: material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra)
In other words, increasing the current has a positive effect on MRR and a negative effect on EWR
Summary
Electro-discharge machining (EDM) is a thermoelectric process during which the heat energy of the spark produced between the electrodes is used to erode materials from the electrodes [1]. The performance of the EDM process is measured by different outputs such as: material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Selection of the electrode materials is one of the more important aspects that require care in EDM. This is because the improper selection of the electrode materials may cause poor machining characteristics. An improper electrode material may cause less MRR, leading to more machining time, leading to high EWR. Many researchers have discussed and investigated the effect of current and electrode material and their effect on the MRR and EWR. Machining characteristics change greatly when using different electrode materials due to the different erosion removal resistance [2]
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