Parametric Investigation of the Effects of Electrical Discharge Machining on Plain D2 Steel

Abstract

Electrical discharge machining (EDM) has emerged as a pivotal non-conventional production technique due to its unique capability to machine without the cutting tool’s physical contact with the workpiece, making it apt for brittle, delicate, and complex materials. This research delved into the influence of operational parameters—pulse duration (Ton), peak current (Ip), duty cycle (T), and gap voltage (Vg)—on machining attributes, namely material removal rate (MRR), electrode wear rate (EWR), and radial overcut (ROC) for AISI D2 steel. Utilizing the Taguchi L9 orthogonal array for experimental design, nine experiments were conducted, followed by signal-to-noise ratio (S/N ratio) computations. Key findings highlighted a 4.02 dB improvement in the S/N ratio for MRR, leading to a 29.13% improvement; a 10.35 dB enhancement in the S/N ratio for EWR, resulting in a 33.33% reduction; and a 2.20 dB increase in the S/N ratio for ROC, leading to a 28.57% increment. ANOVA analyses further underscored the predominant influence of all four parameters. The significance of these findings lies in optimizing the EDM process for increased efficiency, reduced tool wear, and enhanced precision, potentially leading to cost savings and improved production quality in industrial applications.

Process Parameter Optimization for CO2 Laser Polishing of Fused Silica Using the Taguchi Method

“…The ratio of the mean of the squared deviations to the mean of the squared error is the F value for each parameter. ANOVA is a statistical method that is used to determine the interactions of the process parameters used in the test design [18]. An analysis of variance was carried out to study the relative significance of control factors and their contribution to the performance characteristic, i.e., the roughness of the laser polishing surface.…”