performance optimization in electro discharge machining

Abstract

Die sinking Eletro-discharge machining is a popular non-traditional machining process widely newlineused to form complex contour in any conducting material irrespective of its hardness and newlinestrength with high accuracy. In order to use this costly non-conventional machining process in newlinea techno-economical way, researchers are trying continuously in different thrust areas. newlineIn the present research work, only experimental work has been carried out. Three most widely newlineused high strength temperature resistant steels such as D2 steel, INCONEL 718 and INCONEL newline625 have been machined with copper and copper-tungsten tool materials by varying the newlinediameter of tools (i.e 10mm and 15mm). Four input parameters such as input current, pulse on newlinetime, pulse off time and flushing pressure are varied at three levels. In order to economically newlineperform the experiments, Taguchi s L9 orthogonal array is used to obtain the same results as newlineobtained in traditional method where 81 i.e, 34 no. of experiments are required to be performed. newlineSix output parameters such as: material removal rate (MRR), Tool wear rate (TWR), Surface newlineroughness (SR), Percentage of radial overcut (%ROC), Crackwidth (CW) and Surface crack newlinedensity (SCD) were measured for each run of experiments. There are twelve different phases newlineof experiments due to different combinations of workpiece material, tool material and tool newlinedimensions. In each phase 9 different experiments have been performed. As a result of which newline108 nos, of experiments have been carried out. newline newline newline