EDM Electrode Design and Analysis to Enhance Process Performance

Abstract

Electric discharge machining (EDM) is regarded as one of the most energy-efficient manufacturing processes for exceptionally accurate processing of any electrically conductive material, regardless of mechanical properties. EDM is a non-contact process utilized in various industries, including aerospace, industrial, instruments, molds, dies, and medical tools; also, it is beneficial for hard materials with simple or proficient geometries and shapes. Although EDM is for machining "difficult to machine" metals, such as those used in the mold and die industries, metal properties indicate potential capability in the domain of surface modification due to the electrical spark between the tool and the work material. This paper investigates the machining of Alloy steel X210 by using the most affecting parameters and how electrode angles contribute to responses, as MRR, Electrode wear ratio, and surface finish, which the manufacturing industry uses to make die tools, molds, automotive parts, and other products. Electrodes with angles of 0o and 90o are used to machine workpieces using WEDM (dk7740). Electrode Angle, peak discharge current, pulse-on time, and pulse-off time were controllable parameters in this study. While all other criteria are constant, variables have been studied. The effects of the four aspects on the four variables were statistically analyzed using ANOVA by MINITAB. Regression models for the responses were developed. Regression mathematical models have been developed for Alloy steel X210 workpieces to increase productivity and industry results.

Keywords

• EDM
• Electrode Geometry
• Roughness
• MRR
• Optimization