Optimization of CNC Die-Sinking EDM Process Parameters Based on MRR and EWR by Taguchi Method Using Copper Electrode on P20 Tool Steel

Abstract

Optimization using Taguchi methodology is one of the techniques for industries by which manufacturing for quality products at lower cost is achieved. The process parameters, such as current, pulse-ON and pulse-OFF time in electrical discharge machining (EDM) process, give variations in the performance characteristics, such as material removal rate (MRR) on workpiece and electrode wear rate (EWR) on tool while machining P20 tool steel using copper electrode. By conducting Taguchi design of experiments using L9 orthogonal array, the analysis had been carried out. Using Minitab, its response tables and graphs were observed to find out the optimal levels of parameters in the EDM process. Thus, the process parameters for EDM were optimized during machining of P20 steel for achieving the combined objectives of higher rate of material removal and lower wear rate on tool. The obtained results helped to identify the major and minor parameters affecting MRR and EWR.