Parametric optimization of process parameters on performance characteristics using die-sinking EDM with deionized water and kerosene as dielectrics

Abstract

Latest technical advances have brought in the development of new manufacturing materials that are difficult to machine using traditional machining procedures for shaping hard metals and creating deep complicated rounded holes. On the other hand, modern machining processes perform the machining in an extremely effective manner. In the manufacturing / development industry, there are various modern machining processes available amongst Die-Sinking Electrical Discharge Machining (DSEDM) is a fine machining technique for producing deep complex shaped holes in all types of electro-conductive and semi-conductive materials. The most important performance characteristics in DSEDM are Rate of Material Removal (MRR), Rate of Tool Wear (TWR), and Roughness of the Surface (Ra). The present research work deals with the optimization of process parameters (Voltage and Duty Cycle) on a parametric scale on performance characteristics such as MRR and TWR using die-sinking EDM with dielectric fluids include Deionized (DI) water and Kerosene. The experiments are conducted by using Taguchi – Design of Experiments (DOE) technique and the analysis is confirmed by using ANOVA and TOPSIS. It is observed that the MRR is enhanced by utilizing the kerosene as dielectric liquid compared with DI Water but for TWR it is vice versa. In addition to the optimization of control factors, machined holes are characterized in terms of responses such as roundness and radial overcut.