Effect of the Electrical Discharge Machining Parameters on Material Removal Rate

Abstract

This study applies Taguchi's Design and Signal to Noise Ratio as an experimental methodology to enhance and improve the process parameters and the removal rate of the material MRR, to machine the tool steel alloy DIN 1.2080 during discharge machining EDM. Experiments have been carried out in accordance with L9 standard orthogonal array design with four process parameters, namely Electrode Diameter, Discharge Current, Duty Factor and Pulse on time, utilizing the S/N analysis. The following was discovered to be the best process parameter setting: Electrode Diameter at level 3 (25mm), Discharge Current at level 3 (25A), Pulse on time at level 1 (300 μs) and Duty Factor at level 1 (0.65) i.e. Di3, Ip3, Ton1, and η1 considering larger-better approach. The main effect plot results indicated that Pulse on time, and Discharge Current are the most significant parameters for the material removal rate, followed by Electrode Diameter. The Duty Factor is the least affecting parameter on the response. A Regression analysis was used to construct a mathematical model for the reaction between response and inputs, the predicted value of the developed model and experimental value are very close to each other showing significance of the developed model, it is observed that there is good agreement between the predicted and experimental values.