Performance analysis of EDM parameters on silicon nitride-titanium nitride composite for improving geometrical tolerances: an integrated GRA-RSM approach

Abstract

ABSTRACT In the modern context, ceramic composites are being developed not just for increased strength and hardness but also for the ability to manufacture difficult to machine geometries that can use Electrical Discharge Machining. Sparking parameters such as current (I), pulse on time (Ton), pulse off time (Toff), and dielectric flushing pressure (P) are improved with multi-response factors such as material removal rate, Electrode Wear Rate, and Geometrical Errors. The results of the confirmation experiments indicate that machining time was decreased from 12.517 to 10.121 min, Material Removal Rate was increased from 0.0183 to 0.0215 g/min, Electrode Wear Rate was reduced from 0.0024 to 0.0002 g/min, circularity was decreased from 0.175 mm to 0.098 mm, cylindricality was decreased from 0.761 to 0.541 mm, and perpendicularity was decreased from 1.071 to 0.085 mm. By optimizing the data to its optimum level, the gray relational grade has been enhanced to 0.16464. Consequently, the experimental findings suggest that gray relational analysis can be effectively employed to optimize the machining settings of Spark Electrical Discharge Machining for various performance aspects.