Effect of process parameters during electric discharge machining of maraging steel and optimization using Taguchi-DEAR method

Abstract

Purpose The electric discharge machining (EDM) involves electrons discharged from the electrode and machining progresses due to the removal of the material from the component. This a thermal-based machining process primarily used for hard to machine components with conventional methods. This process is used to make intricate cavities and contours. The fabricated part is the replica of the tool material with high surface finish and good dimensional accuracy. This study aims to evaluate the comprehensive effect of process parameters on electric discharge machining of maraging steel. Design/methodology/approach Multiple criteria Decision making (MCDM) techniques are used to select the best parameters by comparing several responses to achieve the desired goal. There are different MCDM techniques available for optimization of machining parameters. In the current investigation, multi-objective optimization by data envelopment analysis based ranking (DEAR) approach was used for machining Maraging C300 grade steel. Findings The Taguchi L9 runs were planned with process parameters such as current (Amp), Tool diameter (mm) and Dielectric pressure (MPa). The effect of process parameters on the responses, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were evaluated. High MRR is found at 15 A current, 14 mm tool diameter and dielectric pressure of 0.2 MPa. Optimum process parameters experiment showed reduced crack density. Originality/value An effort was made successfully to enhance the responses using the DEAR method and establish the decision making of selecting the optimal parameters by comparing the results obtained by machining maraging steel C300 grade.

A comprehensive review of parametric optimization of electrical discharge machining processes using multi-criteria decision-making techniques

“…Table 6 depicts the applications of Taguchi-DEAR method in optimizing EDM processes. Sameer et al (2021) performed EDM operation on maraging steel treating Ip, DT and PF as the input parameters and MRR, SR and TWR as the responses and optimized the said process using Taguchi-DEAR method. In the similar direction, an EDM operation on titanium alloy was optimized by Phan et al (2021) with identification of the optimal combination of EDM parameters as Ton = 1,000 μs, Vg = 55 V and Ip = 40 A which would yield the corresponding values of MRR, SR and TWR as 0.0139 g/min, 9.313 μm and 0.0089 g/min respectively.…”

EBSD Characterization of Microstructure and Micro-texture in a Friction Stir-Welded DP600 Steel

“…In another study [20], the same researchers investigated the effect of tool rotational and transverse speed on the joint microstructure and tensile properties. Sameer and Birru [21] also studied the effect of tool rotational speed on the microstructure and mechanical properties of FS-welded DP600 steel.…”