Parametric Optimization of Material Removal Rate of EDM (AISI-4147) by using Taguchi Approach

Electric discharge machine is a non-conventional machining. In which there is no contact between tool and work piece. By EDM process machining of hard material components that are difficult to machine such as heat treated tool steels, ceramics, composites, carbides, heat resistance steel which are used in die and mould producing industries, aero space and nuclear industries. EDM is a non-contact type technique of material removal and in this spark is used to remove the material from the work piece. Since the EDM is an attractive means of making tool and dies with high accuracy in dimension and surface finish quality of micro scale parts. The present experimental research studies the process parameters that are influencing the machining concert and its productivity. A collective approach is used for the optimization in parameters and performance characteristics which are based on Taguchi method. The experiments are based on Taguchi‟s L9 orthogonal array. The reaction graph and reaction table of each near of machining constraints are took from Taguchi method to select the optimum levels of machining factors. In the work, the machining parameters for thesis are current, pulse on time and pulse off time, which are optimized for minimum tool wear rate (TWR), maximum material removal rate (MRR) and minimum surface roughness during electro discharge machining of AISI 4147. Analysis of Variance is also used to find out variable affecting the various responses mentioned above.