Parametric Optimization for Quality of Electric Discharge Machined Profile by Using Multi-Shape Electrode

Area of Science:

• Manufacturing Engineering
• Materials Science

Background:

• Electrical discharge machining (EDM) is a precise, non-conventional material removal process for electroconductive materials.
• Optimizing EDM parameters is crucial for achieving intricate shapes with high accuracy and superior surface finishes.
• Recent advancements focus on refining EDM techniques for enhanced machining performance and material processing.

Purpose of the Study:

• To optimize electrical parameters of EDM using multi-shaped electrodes.
• To achieve superior surface finish, high dimensional accuracy, and improved post-machining hardness.
• To enhance the overall quality of machined profiles in die steel D2.

Main Methods:

• Experimentation on die steel D2 using a multi-shaped copper electrode.
• Optimization of electrical parameters: spark voltage, current, pulse-on time, and depth of cut.
• Full factorial Design of Experiments (DOE) coupled with regression analysis and ANOVA using Minitab.

Main Results:

• Identified optimized relationships between electrical parameters and output characteristics.
• Demonstrated the significance of each operating parameter on surface roughness, hardness, and dimensional stability.
• Validated experimental findings with statistical analysis for reliable optimization.

Conclusions:

• The study successfully optimized EDM electrical parameters for enhanced surface finish and dimensional accuracy.
• Multi-shaped electrodes and specific parameter settings significantly improve post-machining hardness.
• The findings provide a robust framework for quality enhancement in EDM processes.