Optimization of Process Parameters during EDM of SS304 using Taguchi-Grey Relational Analysis

Abstract

This paper presents the influence of process parameters on machining characteristics during electrical discharge machining of stainless steel SS304. The chosen process parameters are peak current, pulse on time and pulse off time and material removal rate, tool wear rate and surface roughness are selected as machining characteristics. Further, an attempt is made to obtain optimal combination of process parameters that yields maximum material removal rate, minimum tool wear rate and surface roughness simultaneously using Taguchi-grey relational analysis. Experiments were conducted using Taguchi L9 orthogonal array. Results revealed that process parameters peak current, pulse on time and pulse off time having significant affect on material removal rate and surface roughness. However, pulse off time has no significant affect on tool wear rate. Further, optimal combination of process parameters is achieved as when peak current at 24A, pulse on time at 100µs and pulse off time at 35µs. The predicted values of responses are material removal rate was 14.31 mm3/mm, Tool wear rate was 0.77 mm3/mm and Surface roughness was 9.33µm. confirmation experiments were conducted at optimal parametric setting. Predicted values were compared with experimental values and the deviation is 1.31% which was found satisfactory.