Tool wear rate optimization in PMEDM using titanium powder by Taguchi method for die steels

Abstract

Powder mixed electrical discharge maching (PMEDM) is a complex machining process which is controlled by a number of machining parameters. Each machining parameter has its own influence on performance of the process. For achieving the best performance of the electrical discharge machining (EDM) process, it is crucial to carry out parametric design responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness(SR). The objective of this paper is to optimization of input parameters for the TWR in PMEDM using powder titanium are presented. The Taguchi method was applied to the processing parameters to investigate the following: workpiece material, tool material, polarity, pulse-on time, current, pulse-off time, and powder concentration. The analysis used the Taguchi method and given the optimal value for TWR with respective parameters. Electrode material affected the strongest factor, the Taguchi coefficient, S/N of TWR. And the optimal value of TWR was 3.092 mm3/min. Results from optimization calculations and experimentation have demonstrated high accuracy and efficiency.