Title: Optimisation of machining parameters using grey relation analysis for EDM with impulse flushing

Authors: Shailesh Dewangan; Chandan Kumar Biswas

Addresses: Production Engineering Lab, Department of Mechanical Engineering, National Institute Technology, Rourkela-769008, India ' Production Engineering Lab, Department of Mechanical Engineering, National Institute Technology, Rourkela-769008, India

Abstract: The present work demonstrates the optimisation process of multiple responses, i.e., material removal rate (MRR) and tool wear rate (TWR) of electrical discharge machining (EDM) by grey Taguchi analysis. The work piece material was AISI P20 tool steel and a cylindrical copper electrode was used with side impulse flushing. The discharge current, pulse on time, work time, lift time, and inter electrode gap (IEG) were the control parameters of EDM. Taguchi method was used to design the experiment using L27 orthogonal array and the effect of the factors on the responses was studied. These results show that MRR decreases with the electrode lift time whereas working time slightly increases it. TWR is directly proportional to work time, and lift time and inter electrode gap has no significant effect on it. The optimal parameter setting for maximum MRR and minimum TWR was obtained by grey relational analysis.

Keywords: electrical discharge machining; EDM; electro-discharge machining; AISI P20 tool steel; grey relation analysis; GRA; impulse flushing; Taguchi methods; optimisation; material removal rate; MRR; tool wear rate; TWR; orthogonal arrays; electrode lift time; work time; inter electrode gap.

DOI: 10.1504/IJMMS.2013.053826

International Journal of Mechatronics and Manufacturing Systems, 2013 Vol.6 No.2, pp.144 - 158

Received: 09 Feb 2012
Accepted: 04 Sep 2012

Published online: 10 May 2013 *

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