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Process Parameters Optimization for Material Removal Rate & Surface Roughness in EDM of En31 Tool Steel

Jithin Ambarayil Joy and Dong-Won Jung
Department of Mechanical Engineering, Jeju National University, Jeju, Republic of Korea

Abstract—To machine materials for dies, complex cavities & intricate jobs, a non-conventional machining process called electrical discharge machining is used. Areas like aeronautics, die & mold manufacturing, Injection molding etc. find a wide range of applications in this process. Improving the MRR, reducing the tool wear rate & surface roughness is the main challenge for an EDM researcher.

The present study aims at presenting the optimization of die sinking EDM. For obtaining the overall utility value which depicts the overall performance of EDM, Multi-response, optimization techniques is being taken into considerations. The present study reveals the investigation of process parameters on Current, Pulse on time, duty cycle, voltage, spark gap and flushing pressure for Metal removal rate (MRR) and Surface Roughness (SR). The maximum effect on Utility is shown by the pulse on time then flushing pressure, current, spark gap and voltage have their effect but duty cycle proved to be an insignificant factor as shown by the experimental results. The optimum values of MRR & SR are 0.252 g/min & 5.02 μm respectively. The results are further verified by the confirmation experiments.
Index Terms—EDM, MRR, SR, Taguchi method, Utility concept, Optimization

Cite: Jithin Ambarayil Joy and Dong-Won Jung, "Process Parameters Optimization for Material Removal Rate & Surface Roughness in EDM of En31 Tool Steel," International Journal of Mechanical Engineering and Robotics Research, Vol. 8, No. 2, pp. 182-188, March 2019. DOI: 10.18178/ijmerr.8.2.182-188