Study on Performance of EDM Electrodes Produced Through Rapid Tooling Route

Abstract

The present study highlights a multi-objective optimization problem by applying utility concept coupled with Taguchi method through a case study in electric discharge machining of D2 steel by using electrode produced by direct metal laser sintering (LS). The study aimed at evaluating the best process environment which could simultaneously satisfy multiple requirements such as tool wear rate, material removal rate, and surface roughness. As traditional Taguchi method cannot solve a multi-objective optimization problem, to overcome this limitation, utility theory has been coupled with Taguchi method. Depending on Taguchi’s lower-the-better and higher-the-better criteria, individual response characteristics have been transformed into corresponding utility values. Individual utility values have been added finally to compute overall utility degree which serves as representative objective function for optimization using Taguchi method. The present study combined utility theory and Taguchi method for predicting optimal settings. Optimal result was verified through confirmatory test. This indicates application feasibility of the aforesaid methodology proposed for multi-response optimization and off-line control of multiple quality characteristics in electric discharge machining using electrode produced by direct metal LS.