Electrode Wear Research Articles

Effect of ultrasonic assisted EDM based on horizontal vibration on deep and small hole machining.

With the development of science and technology, industrial production requires more and more precise parts processing, precision processing has become a trend. In this trend. The traditional processing methods have been difficult to meet the market demand for micro-hole parts. Therefore, combining the characteristics of EDM and Ultrasound-assisted Machining, a new horizontal Ultrasound-assisted EDM system for deep and small holes is designed and applied in physical machining. The experimental results show that the horizontal ultrasonic vibration of workpiece can promote the efficiency and depth of EDM, and improve the electrode wear and the inner surface roughness of small holes. By comparing the processing effects of different materials, it is found that the processing efficiency and depth of pig iron are better than those of stainless steel. In conclusion, the horizontal ultrasonic vibration system established in this paper not only improves the processing effect of conventional EDM to a certain extent, but also does not affect the spindle feed and working fluid circulation of EDM machine tools. It enriches the research direction of ultrasonic assisted EDM and has broad market prospects.

INVESTIGATION ON ELECTRODE WEAR IN MICRO-EDM DRILLING

Micro-EDM drilling is extensively utilized in various industrial sectors due to its capability to machine all types of conductive materials, irrespective of their mechanical properties. This technology is particularly advantageous for drilling applications requiring high aspect ratios and precision. However, electrode wear, both frontal and radial, poses significant challenges, especially in blind hole drilling. This study proposes a mechanical method to measure electrode geometry through touch operations on a sharp target, varying the spindle rotation angle and Z depth. The method's effectiveness was validated through extensive experiments on Ti6Al4V plates using cylindrical and tubular electrodes of different diameters. The study varied energy types and tested new and steady-state electrodes. Results demonstrated the method's ability to detect changes in electrode tip shape under different conditions, revealing phenomena such as the correlation between electrode runout and wear, and the impact of internal washing on tip shape.

A hybrid GRA-PCA-TOPSIS Technique Optimization of EDD Process Parameter on Drilling of AL8011/B4C/aloevera composites

A class of cutting-edge materials called hybrid aluminum metal matrix composites has been produced for applications such as the automobile, aerospace, and electronics industry and where weight and strengths are crucial factors. In the present research work, AA8011 composite reinforced with boron carbide particles and green aloevera has been fabricated using an economical stir casting process. In this 1% to 3% of boron carbide and 1% to 2% aloevera were used to fabricate the three different combinations of composites. The electrical discharge drilling process variables such as discharge current, pulse-on time, pulse-off time, and dielectric fluid pressure are investigated using the tubular copper electrode on drilling of hybrid composites. Performance aspects including drilling rate, roundness error, taper angle, and electrode wear rate have been analyzed, and the effect of process variables with the response surface methodology–central composite experimental design. The process parameters during the drilling of composites were optimized using a novel multi-criteria decision-making technique called the hybrid grey relational analysis–pulse component analysis–technique for order of preference by similarity to ideal solution method in order to maximize the drilling rate while concurrently minimizing other aspects. The optimum conditions were reached using the hybrid optimization method and a 1.5 mm tubular copper electrode with an input current of 9 Ampere , pulse on time 25 [Formula: see text]s, pulse off time 12 [Formula: see text]s, and pressure 60 kg/cm2. In comparison to the initial settings, the optimal condition shows a 25% faster drilling rate, with a 23% better roundness value, 14% lesser taper angle, and 7% lesser electrode wear rate.

Study on the degradation performance of coking wastewater using an in-situ enhanced Fe2+/Fe3+ cycle dual-cathode Electro-Fenton system

Coking wastewater, characterized by its complex composition, high pollutant concentration, and poor biodegradability, poses a significant challenge for wastewater treatment. In this study, a chitosan-based mesoporous carbon (CPC) and microporous carbon (ZPC) dual-cathode Electro-Fenton system was developed to enhance the in-situ Fe2+/Fe3+ cycle efficiency for the degradation of coking wastewater. The optimal preparation conditions for both electrodes were investigated, as well as the primary factors affecting the degradation performance of the dual-cathode Electro-Fenton system. When the functional carbon loading was 17.5 mg/cm2 and a current of 600 mA was applied, the CPC electrode produced 842 mg/L of H2O2 within 30 min, and the Fe2+/Fe3+ cycle efficiency of the ZPC electrode reached 85.23 %. The initial pH and current intensity had the most significant impact on the degradation efficiency of coking wastewater, achieving a COD degradation rate of 78 % at an initial pH of 3.5 and a current intensity of 600 mA. GC-MS analysis indicated that under 600 mA, nitrogen-containing organics, ethers, and alcohols in the coking wastewater were completely removed. The degradation of simulated wastewater showed that the presence of oxygen-containing compounds inhibited the degradation of nitrogen-containing organics. However, the dual-cathode system experienced significant electrode wear, with reduced hydrophobicity and agglomeration of Fe3+ on the electrode surface impacting its cyclic stability.

Investigation of EDM erosion behavior for Ni-based superalloy using experimental and machine learning approach

The rapid growth of the global population and the consequent increase in manufacturing activities have heightened the need for sustainable practices to protect the environment. Non-traditional manufacturing processes, such as electric discharge machining (EDM), often use oil-based dielectric fluids like kerosene, which emit toxic fumes and aerosols, contributing to environmental pollution. To address this, the reuse of waste cooking oil (WCO) as a dielectric fluid in EDM presents a promising solution. This method not only tackles the issue of waste oil disposal but also supports the circular economy by repurposing waste materials. EDM, frequently criticized for its low cutting rates, can be enhanced by using nitrogen assisted modified Cu electrodes (cryogenically treated (CT)). This study focused on machining the difficult-to-cut nickel-based superalloy, IN718 by incorporating Sillimanite nano-powder with Span-60 (S-60). The erosion performance characteristics such as material removal rate (MRR), electrode wear rate (EWR), and accuracy index (AI) were evaluated. An artificial neural network (ANN) was employed to predict and correlate experimental and predicted values. Significant improvements were achieved using the non-dominated sorting genetic algorithm (NSGA-II) in the confirmation investigations. With a non-treated (NT) Cu electrode, the confirmatory experiments showed a 79.81 % increase in MRR, an 18.99 % decrease in EWR, and a 0.89 % improvement in AI. For the CT Cu electrode, MRR increased by 85.48 %, EWR decreased by 32.90 %, and AI improved by 0.53 % when using optimal processing parameters. This study demonstrates the potential for significant environmental and performance benefits in EDM by reusing WCO and optimizing electrode treatments.

Numerical modelling and experimental investigations to predict the tool wear of copper electrodes during µ-EDM process

The micro electrical discharge machining (µ-EDM) process is one of the most widely used techniques to produce miniaturized components in micro-electro mechanical system (MEMS) applications due to its inherent advantages. This work investigates the wear phenomena and the morphology of the copper electrodes during the micro-die sinking process. A numerical model of a single spark is developed assuming the Gaussian distribution of heat flux to estimate the crater dimensions formed in the copper tool electrode (tool wear) used as a result of electric discharge. The crater dimension attained from the ABAQUS finite element model is validated with experimental results using a single spark test setup. Moreover, the effect of input parameters namely capacitance and voltage on the electrode wear rate and surface roughness is also studied. The crater dimensions from the single discharge study are used to formulate the wear model for different possibilities of crater distribution, such as non-overlapping craters, craters with less than 30 % overlap, and 50 % overlap. The electrode wear rate (EWR) also displayed a decline from 20.4 % to 11.6 % and further to 8 % when the overlap was permitted up to 30 % and up to 50 % for the wear model respectively. The developed model results are further compared with experimental results in terms of the electrode wear rate and depth of erosion and the deviations are found to be 20.33 % and 20.55 % respectively

Electro-Discharge Machining of Microholes on 3d Printed Hastelloy Using The Novel Tool-Feeding Approach

Hastelloy, a nickel-based superalloy renowned for its exceptional resistance to corrosion at high temperatures, is widely used in sectors such as nuclear, aerospace, chemical processing, and pharmaceuticals. Microelectrical discharge machining (μ-EDM) is crucial for generating microholes and channels on Hastelloy. Since it effectively addresses difficulties like work hardening, high strength & wear resistance, and low thermal conductivity in traditional machining. Microholes play a major role in many critical components for precise control of fluids in fuel injectors, managing heat in turbine blades, controlled gas exchange, etc. The current research investigates the drilling of 8:1 aspect ratio microholes machined by 400μm diameter electrodes. This study investigated the influence of tool material (tungsten carbide, carbide drill bit, and brass) on μ-EDM performance. Compared to tungsten carbide and carbide drill bits, brass exhibited significantly lower electrode wear, leading to more precise microholes with reduced overcut and taper angle. However, brass also required a substantially longer machining time. Carbide drill bits offered a balance between wear resistance, machining time, and overcut/taper angle.

Enhancing Surface Quality and Tool Longevity in EDM of D2 Steel Using Copper Composite Tools

Hard material machining and die manufacture are the main applications for electrical discharge machining (EDM). For EDM, conventional electrode materials include graphite, steel, brass, pure copper, and alloys based on copper. Unfortunately, excessive tool wear is a common problem with these materials, which raises the cost of machining. In this investigation, hardened D2 steel was machined using a composite tool made of 90% copper and 10% silicon carbide. The powder metallurgy method was used to create the composite tool. Surface roughness (SR) and electrode wear rate (EWR) were compared to a number of process variables. For experimentation, a response surface methodology based on CCD design in design of experts software was used. SR and electrode wear rate models were created using the CCD approach. Utilizing analysis of variance, the most important factors and their effects on EWR and SR were determined. The lowest tool wear rate of 0.39 gm/min is achieved with a current of 5 Amps, a pulse duration of 100 µs, and a pulse interval of 10 µs with an R2 of 0.9957, which accounts for 99.57% of the variability, the tool wear rate model fits the data very well and obtained lowest surface roughness of 2.8 µm.

Optimization of Material Removal Rate and Wear Rate in EDM Machining of Inconel 625 Using a Novel Nano Al-Ni Composite Electrode: A Response Surface Methodology Approach

The electric discharge machine is a novel machining technique. When the tool and the work item do not communicate. Components composed of difficult-to-machine hard materials. In the current experimental inquiry, the process factors that influence the machining concert process and its effectiveness are explored. The response table for each set of machining limitations is used in conjunction with the response surface methodology in the research to determine the appropriate levels of machining factors. The work's machining input parameters are optimized for maximum material removal rate (MRR) and reduce the electrode wear rate (EWR) when electro-discharge machining Inconel 625 using the tool Nano Al-Ni composite electrode. Another analysis of variance is to identify the factors causing the different answers mentioned above. EDAX was also used to investigate the material composition of the workpiece. Machined workpiece surfaces were evaluated using scanning electron microscopy to assess surface accuracy and microstructural characteristics (SEM). The following conclusions may be drawn from this work. The MRR parameter that is most affected is pulse off time. As pulse-off time lengthens, MRR increases. According to the response graph, the greatest MRR value that can be attained under the ideal parameters of Ip = 8A, T-ON = 50μs, and T-OFF= 100μs is 0.0115 g/min. The magnitudes of MRR range from 0.0091 to 0.044 g/min. Impact of T ON and T OFF: Higher EWR is 0.0022 g/min is seen in runs with T ON = 70 μs and T OFF = 100 μs.

Detection of Nickel Atoms Released from Electrodes in Spark Discharges Using Laser-Induced Fluorescence.

The reduction of greenhouse gas emissions and the effort of carbon neutrality require the improvement of spark-ignition engines in terms of efficiency and capability to operate on renewable fuels. The electrode wear of spark plugs, used for ignition of novel fuels and lean mixtures, emerges as a significant challenge in this transition. Understanding the physical mechanism and influence of spark operation parameters of the wear process is thus important. Compared to the conventional methodology of performing long-term wear tests, laser-based optical diagnostics methods are capable of assessing electrode wear during one single or a few spark discharges. In this work, the necessary initial steps required for performing optical investigations using laser-induced fluorescence (LIF) are presented. Several excitation pathways of nickel atoms were investigated, and 336.96 nm was identified as the optimal one. This excitation approach yielded emissions between 338.75 and 353.58 nm, effectively avoiding the major interference from N2 plasma emission in spark discharges. Additionally, a linear relationship in fluorescence signal intensity with excitation energy up to 400 µJ was observed. These findings indicate the potential of LIF for in situ diagnostics of electrode wear, contributing to engine development in both efficiency and compatibility with sustainable fuels.

The effect of Titanium Carbide (TiC) addition on the performance of Cupro-Tungsten (Cu-W) alloy for spark erosion electrodes used in machining carbide materials

This article focuses on the development and characterization of Copper-Tungsten (WCu) electrodes, enhanced with the addition of nickel and cobalt as activators and titanium carbide (TiC) for improved wear resistance. The electrodes were manufactured using powder metallurgy through cold pressing, followed by sintering-infiltration at 1250°C under a reducing atmosphere of H2. The characterization process involved measuring density, microhardness, electrical conductivity, and SEM/EDX microstructure. Additionally, technological tests were conducted on P35 carbide parts to assess parameters such as material removal rate (MRR), tool wear rate (TWR), and wear rate (WR). The results indicated that the W-Cu-Ni-TiC compact exhibited an improved density of 11.95, while the W-Cu-Co-TiC compact demonstrated the highest MRR. The W-Cu-Co-TiC compact also recorded a lower TWR. Overall, the W-Cu-Co-TiC compact offered the best compromise in terms of electrode-part wear, achieving superior microhardness values of 289Hv. These findings suggest that incorporating transition elements and TiC into WCu electrodes can significantly enhance their performance, making this study a valuable reference for future research aimed at improving electrode wear resistance through material and manufacturing advancements.

Rapid manufacturing of copper-graphene composite EDM electrode for improved machining performance

ABSTRACT Recently, graphene has emerged as reinforcing material for copper-based electric discharge machine (EDM) tools because of its superior electrical, thermal and high melting properties. 3D printing methods to fabricate electrodes are convenient and faster compared to conventional methods. Therefore, this study investigated the fabrication of copper-graphene composite electrodes for EDM using rapid tooling and pressureless microwave sintering. The influence of graphene content on the machining performance was examined, revealing enhanced electrical conductivity and machining efficiency. Electrical conductivity of the composite electrodes having 0.25 and 0.5 wt% of graphene was higher than pure copper. Additionally, upto 89% improvement in material removal rate and upto 14% reduction in electrode wear rate was obtained. Optical study showed an improvement of upto 28% in surface finish of the workpiece machined using composite electrode having 0.25 wt% graphene. A complex shaped composite tool was successfully fabricated and machined cavity was obtained.

Закономерности износа плазмотронов при плазменной резке толстолистового проката на токе обратной полярности

The introduction describes the features of the process of plasma cutting of various metals and alloys using reverse-polarity plasma torches with and the features of cutting thick sheets. The purpose of the work is to study the wear process of plasma torches operating on reverse polarity current when cutting thick rolled sheets of aluminum and titanium alloys. Research methods include optical and scanning electron microscopy, filming of the cutting process and visual inspection of plasma torch elements after receiving specimens. Results and discussion. The section shows the appearance of the main working elements of the plasma torch after cutting in various modes, which led to both stable and gradual wear and to catastrophic failure of the plasma torch. The results of structural studies of the main characteristic zones of nozzles and electrodes after cutting are presented. The studies carried out made it possible to establish the main reasons for the failure of the working elements reverse-polarity plasma torches. The causes of catastrophic failure of plasma torches include failure to maintain the gap between the nozzle and the electrode and melting of the channel of gas supply into the discharge chamber. The wear of nozzles and electrodes in a stable mode can be intensified due to abnormal operation of the starting arc, the presence of manufacturing inaccuracies and excess gas pressure. In conclusion, the main conclusions based on the results of the research are formulated. The process of wear of electrodes, nozzles and body elements of plasma torches during operation at high electric arc power values is described.

Особенности применения электродов-инструментов, изготовленных аддитивными технологиями, при электроэрозионной обработке изделий

Introduction. The paper presents the results of a study of the use of a tool electrode (TE), manufactured by selective laser alloying from MS1 maraging steel powder for copy-piercing electrical discharge machining (EDM). Purpose of the work: experimental study of the features of the use of additively manufactured TE in the EDM of critical products. Research methods. The specimens were prepared using a ReaLizer SLM 50 system. The starting material was spherical MS1 powder with an average particle size of 30 μm. To test the modes and select a TE sample with the least number of surface defects, four manufacturing modes were tested, and the best TE sample was selected for further research. The EDM was carried out on EMT Smart CNC equipment in a dielectric oil environment. The specimens were installed in a clamp with straight polarity and were used as TE; a 0.12C-18Сr-10Ni-Тi steel plate served as the workpiece electrode. The study was conducted using a factorial experiment (type 23) with a central design. The input data of the factorial experiment is the current I (A), voltage U (W), pulse on time Ton (μs). The output parameters were the roughness parameter Ra and tool electrode wear γ. The roughness parameter Ra was measured using a Mahr Perthometer S2. Results and discussion. TE samples were made from MS1 powder using the SLS method; the highest quality TE sample No. 4 was selected for EDM. Empirical equations are obtained that describe the relationship between the roughness parameter Ra and tool electrode wear γ, depending on the EDM modes. At the minimum mode with a current I = 4 A and a voltage U = 50 V, the tool electrode wear is γ = 0.0063875 g. The maximum tool electrode wear is γ = 0.13938 g with a current I = 8 A and a voltage U = 50 V. It is established that at a constant pulse on time Ton = 75 μs, the smallest roughness Ra = 2.83 μm is obtained at a current of I = 4 A and a voltage U = 100 V, and the maximum roughness is Ra = 4.1568 μm at I = 8 A and U = 100 V.

Multi-objective optimization of an EDM process for Monel K-500 alloy using response surface methodology-multi-objective dragonfly algorithm

Monel K-500 is a high-performance superalloy composed of nickel and copper, renowned for its exceptional strength, hardness, and resistance to corrosion. To machine this material more precisely and accurately, Electrical Discharge Machining (EDM) is one of the best choices. In EDM, material removal rate (MRR) and electrode wear rate (EWR) are crucial performance parameters that are often conflicting in nature. These parameters depend on several input variables, including peak current (Ip), pulse on time (Ton), duty cycle (Tau), and servo voltage (SV). Optimizing the EDM process is essential for enhancing performance. In this research, a set of experiments were conducted using EDM on Monel K500 alloy to determine the optimal process parameters. The Box–Behnken design was used to prepare the experimental design matrix. Utilizing the experimental data, a second-order mathematical model was developed using Response Surface Methodology (RSM). R2 value is found to be 99.40% and 96.60% for MRR and EWR RSM-based prediction model, respectively. High value of R2 is indicated is indicated good adequacy for prediction. The mathematical model further used in multi-objective dragonfly algorithm (MODA): a new meta-heuristic optimization technique to solve multi-objective optimization problem of EDM. The MODA is a very useful technique to achieve optimal solutions from the multi decision criteria. Utilizing this technique, a set of non-dominated solutions was obtained. Further, the TOPSIS method was used to determine the most desirable optimal solution, which was found to be 0.0135 mm3/min for EWR and 6.968 mm3/min for MRR. These results were obtained when the optimal process parameters were selected as Ip = 6 A, Ton = 200 µs, Tau = 12, and SV = 41.6 V. Operators can machine Monel K500 by selecting the above-mentioned optimal parameters to achieve the best performance.

The effect of graphene solution on mixed powder electrical discharge milling of Ti6Al4V

Abstract Ti6Al4V is the most widely used materials in aerospace, medical, nuclear power and other fields. However, due to its unique properties such as low thermal conductivity, titanium alloy poses challenges in machining processes. Electrical discharge milling (EDM) is a machining method that utilizes the electrical corrosion phenomenon of pulsed spark discharge between two electrodes to remove materials, which is highly suitable for the machining of Ti6Al4V. This paper investigates a mixed powder EDM approach for titanium alloy using a graphene solution medium known for its green and sustainable characteristics. Compared to conventional deionized water medium processing which without powder particles, the material removal rate can be increased by 50%, the surface hardness after processing was 2.5 times higher than that of the substrate, the electrode wear rate could be reduced by 40%, the surface roughness values were reduced by more than 20%. Besides that, the micro-cracks and micro-pores on the workpiece surface can be significantly reduced. Subsequently, single factor experiments and orthogonal experiments were conducted using material removal rate, electrode wear rate, and surface roughness as process indicators. The influence of processing parameters on process indicators was investigated based on optimal selection method and analysis of variance (ANOVA). Finally, the optimized parameters in graphene solution mixed powder EDM for Ti6Al4V were obtained. When using the process combination A3B3C1D2, the maximum MRR can be obtained.

Optimization of electrical discharge machining parameters for enhanced performance on inconel 718 using Cu-Ni-B4C nanocomposite electrodes and advanced modeling techniques

Abstract This paper investigate into the complex field of electrical discharge machining (EDM) to improve material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR) for the machining of Inconel 718, a difficult-to-machine superalloy. The effects of discharge current, pulse duration, and pulse interval on machining performance were assessed through experiments. Response surface methodology (RSM) and artificial neural network (ANN) models, such as RNN, LSTM, and CNN, were used to optimize. Twenty runs of confirmation experiments were used to confirm the optimal process parameters found by the created models for better machining. For Inconel 718, the novel Cu-Ni-B4C nanocomposite electrode greatly enhanced EDM performance. The ideal configuration increased MRR while decreasing wear and surface roughness. Machined surfaces were inspected using SEM and EDAX analysis. With optimal settings of 50 μs pulse duration and 90 μs pulse interval, increasing current to 8 Amps increased MRR to 0.0118 g min−1, reducing EWR to 0.001 g min−1 and SR to 3.108 μm. Compared to the RNN, LSTM, and RSM models, the CNN model had the greatest R-squared (R2) score of 0.9999, suggesting greater MRR, EWR, and SR prediction.

Influence of machining conditions on dry EDM with workpiece cooling of Inconel 625 alloy in the milling kinematics

One potential eco-friendly variant of electro-discharge machining is dry electro-discharge machining (EDM), in which the liquid hydrocarbon–based dielectric is substituted with a gaseous medium. The primary challenge associated with dry EDM is the excessive dissipation of heat within the machining gap, which restricts its utilisation only to a microscale machining. Consequently, further modifications to the underlying mechanism of the process are being undertaken with the aim of efficient industrialising it on a larger scale. In the present study, a novel approach is proposed to enhance the efficiency of dry-EDM process while using carbon dioxide as a gaseous medium together with introducing additional external workpiece cooling with deionised water. A series of experiments were conducted to determinate the impact of external workpiece cooling with deionised water and the main machining parameters, namely pulse-on time and current intensity gas pressure, on the material removal rate, working electrode wear, and surface integrity of Inconel 625 during EDM in milling kinematics. The results demonstrated that, under the same machining parameters, the wear of the working electrode, the surface roughness, and the thickness of the recast layer were significantly reduced in the EDM with external workpiece cooling in comparison to the dry-EDM process without water cooling. Furthermore, the EDM with coolant exhibited superior performance in comparison to the dry-EDM process due to the fact that there were fewer changes in the surface morphology and chemical composition of the machined material.

An experimental investigation on copper square electrode wear in electric discharge machining of Hastelloy B2

Hastelloy B2 is a high-performance nickel-molybdenum alloy and has been used in micro reactor, pump, pipe, and corrosion-resistant equipment. Square holes are required in the above application components. Although square holes are easily produced by spending more electrodes wear in Electrical Discharge Machining (EDM). Moreover, the square hole with small electrode wear achieved is a challenging task in thermal machining. Hence, in this work, the effects of EDM process parameters on electrode taper angle, electrode radius, electrode wear length and cutting time of Hastelloy B2 are studied. Taguchi based VišekriterijumskoKompromisnoRangiranje (VIKOR) method is used to find the optimum process parameters and compared with Taguchi based Grey Relational Analysis (GRA) method for validation. The results showed that current and pulse duration greatly affects the electrode wear out surface and edges. The square electrodes with sharp edges and surfaces are fully transformed into hemispherical shapes at electrode ends due to an unstable spark with diffusion of heat. Also, the VIKOR method provides an alternative multi-criteria optimization method that enhances the process performance over the grey relational analysis due to comparability, uniqueness, assessment and prediction.

Artificial neural networks-based modelling of effects of cryogenic electrode treatment, nano-powder, and surfactant-mixed dielectrics on wear performance and dimensional errors on superalloy machining

In the present era dominated by Industry 4.0, the digital transformation and intelligent management of industrial systems is significantly important to enhance efficiency, quality, and the effective use of resources. This underscores the need for a framework that goes beyond merely boosting productivity and work quality, aiming for a net-zero impact from industrial activities. This research introduces a comprehensive and adaptable analytical framework intended to bridge existing gaps in research and technology within the manufacturing sector. It encompasses the essential stages of using artificial intelligence (AI) for modelling and optimizing manufacturing systems. The effectiveness of the proposed AI framework is evaluated through a case study on electric discharge machining (EDM), concentrating on optimizing the electrode wear rate (EWR) and overcut (OC) for aerospace alloy Inconel 617. Utilizing a comprehensive design of experiments, the process modelling through an artificial neural network (ANN) is carried out, accompanied by careful fine-tuning of hyperparameters throughout the training process. The trained models are further assessed using an external validation (Valext) dataset. The results of the sensitivity analysis indicated that the surfactant concentration (Sc) has the highest level of influence, accounting for 52.41% of the observed influence on the EWR, followed by the powder concentration (Cp) with a contribution of 33.14%, and the treatment variable with a contribution of 14.43%. Regarding OC, Sc holds the highest percentage significance at 72.67%, followed by Cp at 21.25%, and treatment at 6.06%. Additionally, parametric optimization (PO) shows that EWR and OC overcome experimental data by 47.05% and 85.00%, respectively, showcasing successful performance optimization with potential applications across diverse manufacturing systems.