Abstract
This study presents optimization of multiple performance characteristics [material removal rate (MRR), surface roughness (Ra), and overcut (OC)] of hardened AISI D3 tool steel in electrical discharge machining (EDM) using Taguchi method and Grey relational analysis. Machining process parameters selected were pulse current Ip, pulse-on time Ton, pulse-off time Toff and gap voltage Vg . Based on ANOVA, pulse current is found to be the most significant factor affecting EDM process. Optimized process parameters simultaneously leading to a higher MRR, lower Ra, and lower OC are then verified through a confirmation experiment. Validation experiment shows an improved MRR, Ra and OC when Taguchi method and grey relational analysis were used.
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