Optimization of Operating Parameters for EDM Process based on the Taguchi Method

TL;DR: In this article, the complexity of electrical discharge machining process which is very difficult to determine optimal cutting parameters for improving cutting performance has been reported, and an approach to determine parameters setting is proposed.

Abstract: In this paper the complexity of electrical discharge machining process which is very difficult to determine optimal cutting parameters for improving cutting performance has been reported. Optimization of operating parameters is an important step in machining, particularly for operating unconventional machining procedure like EDM. A suitable selection of machining parameters for the electrical discharge machining process relies heavily on the operators' technologies and experience because of their numerous and diverse range. Machining parameters tables provided by the machine tool builder cannot meet the operators' requirements, since for an arbitrary desired machining time for a particular job, they do not provide the optimal machining conditions. An approach to determine parameters setting is proposed. Based on the Taguchi parameter design method and the analysis of variance, the significant factors affecting the machining performance such as crater diameter,recsat layer,grain size,haz for a hole machined by EDM process, are determined. Index Terms—complexity, Optimization , EDM, significant factors. Electrical Discharge Machining (EDM) was first introduced in the 1940's as a crude device used to cut broken machining tools from expensive in-process parts. Since that time EDM has become a sophisticated and indispensable technology, revolutionizing the tool, die, and mold making industries, and making significant inroads into the production of highly accurate, intricate and difficult to machine production parts. In electrical discharge machining, it is important to select machining parameters for achieving optimal machining performance. Usually, the desired machining parameters are determined based on experience or handbook values. However, this does not ensure that the selected machining parameters result in optimal or near optimal machining performance for that particular electrical discharge machine and environment. In earlier work to solve this task, Lin, Wang, Yan, Tarng (2) used the Taguchi method with fuzzy logic as an efficient approach to determine the optimal machining parameters in the electrical discharge machining process. The Taguchi method can optimize performance characteristics through the settings of process parameters and reduce the sensitivity of the system performance to sources of variation. As a result, the Taguchi method has become a powerful tool in the design of experiment methods (2). However, most published Taguchi applications to date have been concerned with the optimization of a single performance characteristic.