Machining Of Materials Research Articles

Investigation of Dynamic Behavior and Process Stability at Turning of Thin-Walled Tubular Workpieces Made of 42CrMo4 Steel Alloy

During machining, the surface of the machined materials is damaged and tool wear occurs, sometimes even to complete failure. Machining of thin-walled parts is generally cumbersome due to their low structural rigidity. The study deals with the effect of the feed rate and the thickness of the thin-walled part on the dynamic behavior and stability of the turning process during the roughing and finishing of thin-walled tubular workpieces made of steel alloy 42CrMo4. At the same time, the cutting forces and deformations of the workpiece were also evaluated via numerical and experimental approaches. The numerical study is based on a three-dimensional (3D) finite element model (FEM) developed using the ABAQUS/Explicit frame. In the model, the workpiece material is governed by the behavior law of Johnson–Cook. Numerical and experimental results show that the cutting forces and the quality of the machined surface depend not only on the choice of cutting parameters but also on the dynamic behavior of thin-walled parts due to their low rigidity and low structural damping during the machining operation. Cutting forces are proportional to the feed rate and inversely proportional to the thickness of the part. Their variations around the average values are low for roughing tests where the wall-part thickness is higher or equal to 3.5 mm. However, these variations intensify for finishing tests where the wall thickness is less or equal to 1.5 mm. Indeed, the recorded FFT spectra for a finishing operation show several harmonics that occurred at around 550 Hz, and the amplitude of the peaks, which describes the level of power contained in the signals, shows an increase similar to that of the amplitudes of the temporal signal. The flexibility of the part generates instability in the cutting process, but the frequencies of the vibrations are higher than the frequency of rotation of the part.

Creation of an Aluminum Alloy Template with a Surface Structure by Micro-Milling for Subsequent Replication of the Microstructure to Achieve Hydrophobicity

This research paper focuses on the fabrication of a microstructure based on a natural structure pattern of hydrophobic properties using micro-milling technology, followed by an investigation of the dimensional accuracy, roughness, and replication of the fabricated microstructure. Design, modeling (CAD system), fabrication, and replication are the steps of this process. Knowledge of biomimetics was used to select the microstructure. The main research aim of the experiments is to verify and extend the applicability of conventional CNC manufacturing technologies to obtain a functional surface structure. The micro-milling was carried out on a conventional DMG MORI CNC machine, a CMX 600 V three-axis horizontal milling center, using an external high-frequency electric spindle clamped to the machine. The machined material was aluminum alloy EN AW 7075. The tool was a 0.1 mm diameter double-edged ball mill made of sintered carbide and coated with TiSiN. The cutting conditions were determined according to the tool manufacturer’s recommendations. To compare the achieved accuracies, the same microstructure was fabricated using PLA technology. For subsequent replication of the sample, the negative of the selected microstructure was created and machined. Subsequently, a positive microstructure was created using the silicone impression material by the replication process. This paper and the experiments performed extend the technical knowledge in the field of manufacturing surface functional structures and confirm the possibility of manufacturing the designed structures using chip and laser machining technology, with achieved discontinuities in the range of 3 to 50 μm. They also highlight the issues of replication of such structures with respect to critical manufacturing locations (geometrical parameters of the structures affecting the functional properties of the structure, venting, replica defects, etc.).

Effect of ceramic type and thickness on the masking ability of chairside machinable all-ceramic crowns.

This study aimed to evaluate the influence of ceramic type and thickness on the masking ability and final aesthetic effects of chairside machinable all-ceramic crowns. Six kinds from three types chairside machinable ceramic materials (IPS e.max CAD HT/MT/LT, IPS Empress LT, and VITA Suprinity HT/T) in shade A2 were fabricated to slice specimens into 1.0, 1.5, and 2.0 mm-thick sections (n=10). The color parameters of the specimens against black and white tiles and four resin substrates (A2, A4, B3, and C4 shade) were measured with a spectrophotometer. The translucency parameter (TP) was calculated using color parameters measured over standard white and black backgrounds. The color differences (ΔE) were calculated between there substrate shades (A4, B3, C4 ) and A2 shade (control group). Two-way analysis of variance (ANOVA) was performed on the TP values. The two va-riables were ceramic type and ceramic thickness. Three-way ANOVA was used to determine the effects of ceramic materials, ceramic thickness, and substrate shades on the ΔE values, followed by Tukey test for multiple comparisons (α=0.05). Ceramic type, ceramic thickness, and substrate shade significantly affected the ΔE values (P<0.001). The L* and b* values of the specimens increased with increasing ceramic thickness, except in substrate A2, whereas the ΔE values decreased. The color difference of all 1.0 mm-thick specimens or all specimens over the substrates C4 shade exceeded the clinically acceptable threshold (ΔE>3.3). The masking ability of chairside machinable all-ceramic crowns is influenced by ceramic type and thickness, and ceramic material. The thickness of ceramic less than 2.0 mm cannot mask the gray shade abutment.

Achieving Metallurgical Bonding in Aluminum/Steel Bimetallic Castings

Aluminum castings are increasingly being used in automotive powertrain and structural applications for vehicle lightweighting. Cast aluminum parts often need to be machined and joined to steel components in multi-material systems. Bimetallic components produced by casting aluminum over steel substrate are advantageous due to the elimination of machining and traditional dissimilar material joining processes. However, forming a strong metallurgical bonding during overcasting process has been challenging. In this paper, the effects of processing conditions such as substrate surface preparation, pre-heating temperature, melt conditions as well as casting design were studied by investigating the bimetallic interfaces for aluminum A319 casting alloy and a high alloy steel substrate in a sand-casting process. Zn and Al-based substrate coatings were evaluated. The experimental results suggest a metallurgical bond between aluminum and steel can be formed during the sand-casting process via high temperature diffusion with or without coatings. Al-based substrate coating prior to overcasting results in the formation of a continuous layer of intermetallics at the bimetallic interface, with large Al–Si–Fe intermetallics penetrating the cast aluminum.

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

The modeling of machining process characteristics and, in particular, of various cutting processes occupies a significant part of modern research. Determining the thermal characteristics in short hole drilling processes by numerical simulation is the object of the present study. For different contact conditions of the workpiece with the drill cutting inserts, the thermal properties of the machined material were determined. The above-mentioned properties and parameters of the model components were established using a three-dimensional finite element model of orthogonal cutting. Determination of the generalized values of the machined material thermal properties was performed by finding the set intersection of individual properties values using a previously developed software algorithm. A comparison of experimental and simulated values of cutting temperature in the workpiece points located at different distances from the drilled hole surface and on the lateral clearance face of the drill outer cutting insert shows the validity of the developed numerical model for drilling short holes. The difference between simulated and measured temperature values did not exceed 22.4% in the whole range of the studied cutting modes.

Effect of Roller Burnishing and Slide Roller Burnishing on Surface Integrity of AISI 316 Steel: Theoretical and Experimental Comparative Analysis

The article presents a new method called slide roller burnishing (SRB) for the cold working of cylindrical surfaces on machine tools implemented with a novel multi-functional device. The machined material is chromium–nickel austenitic stainless steel. The deforming element is a toroidal roller whose axis crosses that of the workpiece. As a result, a relative sliding velocity occurs in the contact zone between the roller and the machined surface. The sliding velocity vector is set using the burnishing device. The theoretical background of SRB is presented. When the two axes are parallel, the well-known roller burnishing (RB) method is implemented. Thus, RB is a special case of SRB. Both processes are realized using the multi-functional burnishing device. The RB process was studied experimentally and optimized according to three criteria, based on the relationship between the surface integrity and operating behavior of the respective component, to achieve three processes: smoothing, hardening, and mixed burnishing. Using the optimal RB parameters obtained, the dependence of the results of SRB on the crossing angle was investigated and optimized. A comparative analysis was performed between the optimized RB and SRB processes (respectively for their three variants: smoothing, hardening, and mixed) based on geometrical and physical–mechanical characteristics of the surface integrity. The main advantage of the SRB is that it provides smaller height roughness parameters (improvement by 42%) and a higher surface microhardness (improvement by 7%) than RB.

Impact of cryogenic treatment on the performance of coated tungsten carbide inserts during machining of EN24 grade alloy steel

AbstractToday's industries need to be more productive, especially those that shape and machine materials. As a result, engineers and scientists are seeking for cutting tool materials and technologies that have high hot hardness, chemical stability, wear resistance, and toughness while also improving tool life or contact time. Cryogenic treatment of cutting tools has been proven to be a good way for increasing the contact time of any cutting tool material. This study presents the results of turning alloy steel (EN24 grade) using P20 grade carbide inserts under various conditions under continuous machining. Cutting speeds varied from 100 to 500 m/min (in increments of 100 m/min), with feed rates ranging from 0.1 to 0.4 mm/rev in stages of 0.1 mm/rev and a constant radial depth of cut of 1.5 mm were considered under dry machining conditions. Cryogenic treated/coated inserts are better than other inserts in terms of tool life for optimized parameters such as cutting speed 100 m/min, feed rate 0.1 mm/rev, and depth of cut 1.5 mm, according to the study's findings. Under similar conditions of cutting speed, feed rate, and depth of cut, coated/cryotreated inserts had a tool life increase of about 97.5% over uncoated/untreated inserts, a 50.58% increase over uncoated/crytreated inserts, and a 23.89% increase over coated and untreated inserts, respectively.

Calculation of force parameters of workpiece machining process with end mill cutters

The aim is to develop and validate an operational methodology for calculating the force parameters and characteristics of the tool and the process of milling structural materials with end milling cutters. The structural schemes of machining and force models of oblique cutting processes in the modes of axial tool feed and continuous plastic deformation of the processed material were used when developing the method of preliminary calculation of the total axial force working on the cutting edge of end milling cutters. The rotating tool tests were conducted on a Hermle UWF 1202 H 3-axis machining center supplemented with a Kistler piezoelectric dynamometer (model 9272). Authors suggested, developed and tested the preliminary calculation method applied to the force characteristics of the machining process of workpieces by end milling cutters, considering how the energy power of ductile fracture of the machined material affects the process. Contact friction arising on the front and rear surfaces of the cutting tool does not reach the limiting value being subject to the Coulomb – Amonton law, that is, it is estimated by the dependence directly proportional to the normal pressure. After calculations, we defined the materials of the workpiece for milling, that is 45 steel (AISI 1045), and the end two-tooth cutter, uncoated T14K8 alloy, which was used to produce samples. The following milling modes were established: 4 mm boring depth; 50, 100 and 150 m/min cutting speeds; 0.05 and 0.1 mm/rev cutting tool feed. Deviation of the measured values of axial cutting force from the calculated values in the range of changing values of tool feed rate was found to be no more than 11%, and in the range of changing values of cutting speed no more than 15%. The developed calculation and analytical methodology for estimating force parameters of the machining process by end milling cutters provides an increase in the efficiency and reliability of the preliminary prognostic calculation of operating parameters and characteristics of cutting elements of end milling cutters.

Novel study on investigating the mechanical, microstructure morphological, and dry sliding wear characteristics of grey cast iron GG25 with copper additions for valve guides in internal combustion engine

Introduction: The performance functionality efficacy of the engine’s valve train assembly is considerably affected by the valve guide. Material selection is impacted by the prolonged operational lifespan of engines, which favours casting and machining materials such as cast iron. The intent of this study is to examine the dry sliding characteristics of GG25 cast iron with copper additives. Discovering the ways in which variations in load and sliding velocity impact wear characteristics is of paramount significance.Methods: The research entailed the examination of wear characteristics across various environmental conditions. Loads were varied at 30 N, 40 N, and 50 N while maintaining a 1 m/s velocity constant. In the same manner, sliding velocities of 0.5 m/s, 1 m/s, and 2 m/s were varied while a constant load of 30 N was maintained. Experimental techniques were carried out at ambient temperature. Throughout the investigations, frictional forces and the coefficient of friction were also determined. The wear mechanisms of samples that had become deteriorated or worn-out were examined by employing a scanning electron microscope when combined with EDX analysis.Results: A rise in the normal load from 30 N to 40 N led to a twofold rise in wear losses, measuring 417 microns as compared with 222 microns previously. The range of wear losses observed at moderate speeds (0.5 m/s–1 m/s) was 133–222 microns. Conversely, the maximum wear loss observed was 1,226 microns at elevated sliding velocities of 2 m/s, in contrast to 617 microns at higher normal loads of 50 N. Additionally, the research discovered that normal load is more pronounced when both loading and speed are moderate, whereas sliding speed becomes more substantial when both are raised, culminating to higher wear losses.Discussions: In summary, the research highlights the considerable effect that normal load and sliding speed have on the prevalence of wear losses. In conditions of moderate loading and velocity, the influence of normal load is more significant. However, as sliding accelerates, it becomes the predominant factor. An analysis of frictional forces as well as the coefficient of friction indicated that under loading conditions of 30 N–50 N, the friction coefficient raised from 0.238 to 0.43. The wear mechanisms, as discerned via scanning electron microscopy and EDX analysis, underscored the considerable impact of increased sliding velocity on wear loss in comparison to conditions of higher loading.

Liquid crystalline elastomer self-oscillating fiber actuators fabricated from soft tubular molds.

The self-oscillation of objects that perform continuous and periodic motions upon unchanging and constant stimuli is highly important for intelligent actuators, advanced robotics, and biomedical machines. Liquid crystalline elastomer (LCE) materials are superior to traditional stimuli-responsive polymeric materials in the development of self-oscillators because of their reversible, large and anisotropic shape-changing ability, fast response ability and versatile structural design. In addition, fiber-shaped oscillators have attracted much interest due to their agility, flexibility and diverse oscillation modes. Herein, we present a strategy for fabricating fiber-shaped LCE self-oscillators using soft tubes as molds. Through the settlement of different configuration states of the soft tubes, the prepared fiber-shaped LCE oscillators can perform continuous rotational self-oscillation or up-and-down shifting self-oscillation under constant light stimuli, which are realized by photoinduced repetitive self-winding motion and self-waving motion, respectively. The mechanism of self-oscillating movements is attributed to the local temperature oscillation of LCE fibers caused by repetitive self-shadowing effects. LCE self-oscillators can operate stably over many oscillating cycles without obvious performance attenuation, revealing good robustness. Our work offers a versatile way by which LCE self-oscillators can be conveniently designed and fabricated in bulk and at low cost, and broadens the road for developing self-oscillating materials for biological robotics and health care machines.

Intelligens asztal kiszolgálása fuzzy alapú ütemezési módszer segítségével

This paper presents a fuzzy logic-based scheduling method, the Compact Mamdani Fuzzy Inference System (CMFIS), for improving decision-making in manufacturing. CMFIS allows quick evaluation of various scheduling scenarios and can replace shift managers by efficiently handling multiple objectives like prioritization, production capabilities, and time uncertainties. A case study at ESZO Ltd. illustrates CMFIS’s application in optimizing cutting operations. The system considers machine capacities and material dimensions, dynamically adjusting machine assignments for efficient production. Configured through an Excel-based framework, it processes inputs and produces clear outputs through defuzzification, offering a practical tool for enhancing manufacturing decision-making.

Adaptive Ensemble Learning for Machine Tool Prognostics from Meta-Feature-Based Context Information

Model-based condition monitoring systems are widely used for the maintenance planning of manufacturing systems. With further digitalization, these models are more dependent on data. However, most studies are limited to single product or machine working conditions. Context information, such as machine parameters, material information, or environmental parameters are often ignored, neglected, or directly fed into prediction models. In this study, we present a new method called MetaSPX that leverages the context information to adapt the weights of a prediction ensemble. Models are only trained on single multi-variate run-to-failure time series and then added to the ensemble. Spatial proximity calculations of meta-features of the context information, combined with cross-validation knowledge of the ensemble members, are the main drivers of this method. It is tested on a Turbofan data set and compared against a single support vector regression model and an averaging ensemble. The results show a 67% reduction of the average prediction error starting at only two ensemble members compared to the averaging ensemble.

ПРИМЕНЕНИЕ СИЛОВЫХ КОМПОЗИТНЫХ КОНСТРУКЦИЙ ДЛЯ МАШИН АПК

The equipment involved in the agro-industrial complex is subject to active wear and corrosion. The modern solution is to replace the body steel elements with composite ones, but they have not become widespread due to some conservatism of the industry. (Research Purpose) The research purpose is substantiating the effectiveness of the use of polymer composite materials for power body elements of agricultural transporting machines. (Materials and methods) It was noted that the replacement of traditional steel products with composite ones makes it possible to achieve a significant reduction in the mass of products while increasing their reliability, increasing the resource due to the absence of corrosion destruction and minimizing the cost of conservation and storage. (Results and discussion) A comparative analysis was performed using the example of a trailer of an agricultural vehicle, all-metal and composite versions of the side design were considered. The presented options were substantiated on the basis of a qualimetric assessment by an expert method according to the criteria: cost, prospects, material consumption, environmental friendliness, maintainability, corrosion and wear resistance. Analysis of the calculation result showed that the experts preferred the composite version compared to the traditionally used steel sides. An accumulation histogram was constructed according to the data obtained, showing the significance of the final assessment for each criterion (Conclusions) Proved the feasibility of introducing power body elements based on polymer composite materials for machines of the agro-industrial complex. A design based on polymer composite materials of the side of an agricultural trailer in the form of a five-layer rectangular plate of sandwich-structured type capable of withstanding loads arising during operation has been proposed. The use of this design will significantly reduce the mass while increasing corrosion resistance and reliability, which will reduce the cost of repair, maintenance and consumption of fuel and lubricants.

The research of the influence of traverse speed and depth of cut on surface roughness in abrasive water jet machining

The main goal in today's production is to make as many products as possible in the shortest possible time. When machining with an abrasive water jet, this means that it is necessary to cut with the highest possible traverse speeds. Machining with a high traverse speed results in an increase in the surface roughness parameters of the surface machined with an abrasive water jet. With the increase in the thickness of the machined material, i.e. the depth of the cut, this is more and more pronounced. The aim of this work is to determine the influence of traverse speed on the roughness of the machined surface, Ra. Also, the influence of the thickness of the samples on the roughness of the processed surface, Ra , was investigated. The material of the samples was AlMg3 of different thicknesses (6, 8, 10 and 12 mm). The samples were cut with traverse speed of 200, 400, 600, 800, 1000 and 1200 mm/min. The roughness parameter of the machined surface, Ra, was measured at different depths, h and at several places along the samples. Based on the measured values of Ra , it was concluded that with the increase in traverse speed, the roughness of the machined surface increases. It was observed that the roughness parameter Ra at the same depth of measurement, h, has approximately the same values. The mathematical model, that describes the influence of traverse speed on the roughness of the machined surface was developed. This model showed satisfactory agreement with the measured values.

Fatigue behaviour of wire arc additively manufactured sheet material

Wire arc additive manufacturing (WAAM) is a metal 3D printing technique well recognised in the construction sector for its high efficiency, cost-effectiveness and flexibility in build scales. However, there remains a lack of fundamental data on the structural performance of WAAM elements, especially regarding their fatigue behaviour. A comprehensive experimental study into the fatigue behaviour of WAAM steel plates has therefore been undertaken and is reported herein. Following geometric and mechanical characterisation, a series of WAAM coupons was tested under uniaxial high-cycle fatigue loading. A total of 75 fatigue tests on both as-built and machined coupons, covering various stress ranges and stress ratios, have been conducted. The fatigue test results were analysed using constant life diagrams (CLDs) and S-N (stress-life) diagrams. The CLDs revealed that the fatigue strength of the as-built WAAM steel was relatively insensitive to the different stress ratios. The S-N diagrams showed that the surface undulations resulted in a reduction of about 35% in the fatigue endurance limit for the as-built WAAM material relative to the machined material, and a reduction of about 60% in fatigue life under the same load level. Preliminary S-N curves were also proposed for the WAAM steel.

CoCrMo Alaşımının Toz Katkılı Elektrik Deşarj ile İşlenmesinde Malzeme Kaldırma ve Takım Aşınma Hızının Cevap Yüzeyi Modellemesi

Electric discharge machining (EDM) is commonly used in implant manufacturing due to the challenge of machining materials that are widely employed in these applications. The study applies response surface methodology to model the impact of powder concentration and machining parameters in powder mixed EDM of CoCrMo alloys, a prevalent material for implantation. AISI 316L stainless steel was selected as the electrode material, while Ti6V4Al was chosen as the additive powder based on their biocompatibility properties. An experimental design was created using a Taguchi L16 array, which involved selecting 4 levels for each parameter of additive ratio, discharge current, pulse on time, and pulse off time. Regression models were developed for material removal rate (MRR) add tool wear rate (TWR) with satisfactory coefficients of determinations (0.87). Effect of the process parameters on MRR and TWR were analysed by means of 3D response surface plots. As a result of the modeling, it was revealed that discharge current, puls on time positively affected MRR, powder concentrations and puls off time negatively affected it. On the other hand, all of the considered process parameters have increasing effect on TWR.

Investigating surface integrity, corrosion resistance and biocompatibility of 316L steel using carbon nanotube-assisted EDM process

316L steel employed in biomedical applications has experienced mechanical failure triggered by insufficient biological reactions, a high corrosion rate, and surface impurities. Furthermore, the attenuated surface induced by corrosion and wear releases toxic elements, causing inflammatory effects. The prime aim of this research is to evaluate the carbon nanotube (CNT) based coating for enhancing surface integrity, corrosion resistance, and biological responses. This research also aims to comprehend the relationship between electric discharge machining (EDM) process variables and material properties. Several characterisation techniques, including scanning electron microscope (SEM), field emission scanning electron microscope (FESEM), atomic force microscope (AFM), electron dispersive X-ray (EDX), MTT assays, powder X-ray diffraction (XRD) and potentiodynamic polarisation are utilised. The addition of CNT forms a nanoporous and thin coating of 10.3 μm, resulting in a crack-free surface with an adhesion strength of 23.77 MPa. A low corrosion rate (0.0012 mm/year) and almost 85 % of alive cells are observed on the coated surface of 316L steel. This research shows a method to form carbide and oxide-based coating for biomedical applications.

Measuring and Analyzing the Process Capability of Productivity – An Applied Study in the Al-Tahady Factory for the Production of Filters

This study addressed concerns related to increased percentages of damaged and re-worked production, heightened demand for factory products, and lack of awareness of the approved Sigma (σ) level during manufacturing, and associated deviations in the manufacturing process. The primary research problem was to assess the manufacturing process's stability and capability to consistently produce conical filters that meet required specifications. The study followed a sample-based approach, where twenty samples, each containing four observations, were collected continuously over a period of seven days. For each sample, the mean (X ̅) and range (R) were calculated. The mean X-Double bar of 319.32 and the average range R-bar of 0.848 were obtained through data analysis. The main findings revealed that, on average, the manufacturing process was relatively close to the target value (X-Double bar = 319.32). However, the presence of several data points outside the control limits indicated potential variability in the process. The average range (R-bar = 0.848) highlighted certain variations in the manufacturing process, which might contribute to issues like damaged or re-worked production. The study identified the need for further investigation to determine the root causes of these variations, which could include machine malfunctions, material fluctuations, or operator errors. By addressing these concerns and reducing process variability, the factory can enhance product quality, decrease waste, and improve customer satisfaction. In conclusion, continuous process monitoring and improvement initiatives, such as Six Sigma, are essential for achieving greater process capability in conical filter manufacturing. This research contributes valuable insights into process performance and provides a basis for implementing corrective actions to ensure consistent product quality and meet customer demands.

The Impact of Temperature on the Electric, Magnetic, and Thermal Properties in the Selection of Ferromagnetic Materials for Traction Machines

The Impact of Temperature on the Electric, Magnetic, and Thermal Properties in the Selection of Ferromagnetic Materials for Traction Machines

Machining of EN19 steel using cryogenically cooled electrode material in electric discharge machining

The machining of high-strength alloys like EN19 steel poses significant challenges due to their inherent hardness and susceptibility to surface defects during conventional machining processes. In this study, we explore a pragmatic approach to address these challenges by investigating the implementation of cryogenically cooled electrode materials in electric discharge machining (EDM) for EN19 steel. Specifically, cryogenic treatment is applied to copper electrodes with varying soaking durations of 12 and 24 h. The research considers input process parameters, including peak current ( IP), pulse on time ( Ton), flushing pressure, and soaking duration. Material removal rates (MRR), electrode wear rate (EWR), and surface roughness (SR) are considered as the response parameters. To optimize these input parameters, the study employs the VIKOR technique. Improving the in-depth analysis, our investigation incorporates using COMSOL Multiphysics simulation to intricately model the mechanical aspects of single-spark EDM, mainly focusing on the thermal and structural characteristics of both electrodes and the workpiece. The simulation lends strong support to the experimental findings in relation to MRR and EWR. The experimental data demonstrates notable enhancements after a 24 h cryogenic soaking period for copper electrodes. Specifically, we observed a remarkable 77.36% increase in electrical conductivity, a substantial 20% augmentation in MRR, a significant 39% reduction in EWR, and a noteworthy 9.8% decrease in SR. The meticulous synergy of experimental exploration, optimization, and simulation offers a transformative outlook toward augmenting machining efficacy and prolonging electrode longevity, particularly in the context of EDM.