Abstract
Electrical discharge machining (EDM) is one of the most extensively used non-traditional material removal processes for difficult-to-cut materials. The full potential of the EDM process has not yet been exploited due to its complicated discharge mechanism. Though a lot of research has been done to improve the process performance, optimal selection of process parameters for the best performance measures still remains a challenge. Parameter optimization is one of the techniques used in manufacturing processes to achieve best manufacturing conditions, which is an essential need for industries towards manufacturing of higher quality products at lower cost. In this paper, the cutting of hot work tool steel 2714 using electro discharge machining process with copper and graphite electrodes has been investigated. In this work L27 (3*4) orthogonal array based on the Taguchi experimental design is utilized to plan the experiments. Raw data is assessed by the Analysis of Variance (ANOVA) to find optimal conditions for response parameters. The main machining parameters such as pulse-on time, pulse-off time, discharge current, average machining voltage are chosen to determine the EDM response parameters such as material removal rate, surface roughness and gap size. Response tables and graphs are used to find the optimal parameter levels in the EDM process. Key words: Electrical discharge machining (EDM), tool steel 2714, Taguchi approach, material removal rate, surface roughness and gap size.
Highlights
Electrical discharge machining (EDM) is an extremely prominent machining process among newly developed non-traditional machining techniques for difficult-to-cut materials
EDM is especially wellsuited for cutting intricate contours or delicate cavities that would be difficult to produce with a grinder, an end mill or other cutting tools
Physical and metallurgical properties do not create any limitation for the materials to be machined on EDM as there is no physical contact between tool and work piece (Yan et al, 2000)
Summary
Electrical discharge machining (EDM) is an extremely prominent machining process among newly developed non-traditional machining techniques for difficult-to-cut materials. The Taguchi method is used to determine the optimal machining parameters for maximum material removal rate, minimum surface roughness and minimum gap size in EDM operations. The Taguchi method, an effective and powerful tool for experimental design of the performance characteristics was used to determine the optimal machining parameters for maximization of MRR and minimization of SF and (GS) in EDM
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