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Abstract: Electric Discharge Machining (EDM) is the electrical energy and turns it into thermal energy
through a series of discrete electrical discharges
a unconventional machining process where intricate
occurring between the electrode and work piece
and complex shapes can be machined. Only
immersed in an insulating dielectric fluid . Electrical
electrically conductive materials can be machined by
Discharge Machining (EDM) is a process of material
this process. These materials are being widely used in
removal using an accurately controlled electrical
die and mould making industries, aerospace,
discharge (spark) through a small gap (approximately
aeronautics and nuclear industries. In this work DIN
10 to 50 microns) filled with dielectric fluid between
1.2714 steel is the material used for the machining
an electrode and a work piece. The hardness of the
purpose and Copper is used as an electrode. In this
work piece has no effect on the process. Electrically
process Taguchi approach is used to create L27
conductive material is removed by controlled erosion
orthogonal matrix. Experiments were conducted with
through a series of electric sparks of short duration and
the L27 orthogonal array based on the Taguchi
high current density between the electrode and the
method. Moreover, the signal-to-noise ratios
work piece, both the work piece and tool is submerged
associated with the observed values in the experiments
in a dielectric bath, containing kerosene or distilled
were determined. The purpose of ANOVA to see the
water. During this process thousands of sparks per
individual effect of control factors on MRR and TWR.
second are generated, and each spark produces a tiny
In the present work, Optimization of TWR on EDM
crater in the material along the cutting path by melting
conducted by using Taguchi and ANOVA.
and vaporization. The objective of the present work is
Keywords: Die sinking EDM machine, tool wear rate,
to find a suitable process parameters to minimize the
Taguchis method, ANOVA
tool wear rate using DIN 1.2714 as a work piece steel
and square copper electrode as a tool and dielectric
1. INTRODUCTION
flushing. The machining parameter selected are
Electrical-discharge machining (EDM) is an
discharge current, pulse on time ,pulse off time ,
unconventional, non-contact machining process where
voltage , fluid pressure of the tool using Taguchi
metal removal is based on thermo-electric principles.
design approach analyzing the responses of EWR.
In this process, the material removal mechanism uses
The Taguchis method is used to formulate the
5. TAGUCHI DESIGN
Taguchi Method was proposed by Dr. G. Taguchi
in the year 1950. Signal represents the effect on
the average response while the noise is a measure
of the influence on the deviation from the average
response. The S/N ratio is the ratio of the mean
(Signal) to the standard deviation (Noise). This
Fig 1: Die sinking EDM ratio helps to identify the optimum level of
The work piece and tool were connected to the process parameters. A high S/N ratio is desirable
negative and positive terminals of the power supply, as the signal level is much higher than the random
respectively. The dielectric fluid used here is noise level that leads to best performance. The
kerosene. The time taken for machining was calculation of S/N ratio depends on the quality
recorded. The experiments were conducted in the characteristics of the product or process to be
order of L27 orthogonal array. At the end of each optimized. The equation for calculating S/N ratios
experiment, the work piece was removed from the for larger is better and smaller is better .In the
machine, washed, dried and weighed on an study, a three factor mixed level setup is chosen
8. REFERENCES
[1] Khanra A K, Pathak L C and Godkhindi M M,
Application of new tool material for electrical
discharge machining (EDM), Bull. Mater. Sci.,
Indian Academy of Sciences Vol. 32, No. 4, Pg. 401
405, 2009.