Comparative Study & Optimization of EDM Process Parameters Using Different Shape of Tool

Mechanical Engineering

The correct selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM). It is a capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries. EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The workpiece material selected in this experiment is Stavex taking into account its wide usage in industrial applications. In today’s world Stavex contributes to almost half of the world’s production and consumption for industrial purposes. The tool material is copper & brass. The input variable parameters are current, pulse on time and pulse of time. Taguchi method is applied to create an L9 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR), Tool Wear Rate (TWR) and Overcut (OC) study and investigate.

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