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avdesh.sharma@gla.ac.in
Abstract
To pick ideal or close to ideal cutting conditions in different sorts of metal cutting
strategy overhaul issues, it joins the utilization of at any rate one of the current
appearing and streamlining methods, making the structure a bound together and
persuading mean. The Electrical Discharge Machining (EDM) is perhaps the most
striking and most saw non-customary machining measure used. In this current work a
figure is made for ideal game plan of limits from a gathering for most outrageous
material removal rate (MRR) and least wear rate (TWR). A lot of investigations reliant
on L9 display obtained by Taguchi strategy are performed for four data boundary (peak
current, pulse on time, pulse off time and gap voltage), all of them having 3 levels of
characteristics. The results of each set of investigation is recorded for evaluating MRR
and TWR. The results got for MRR and TWR are analysed using TOPSIS methodology
for confirmation of ideal course of action of cycle boundaries of EDM which gives
most outrageous MRR and least TWR. Results obtained here show that the model
embraced here has a sufficient display for progression.
Keywords: EDM Machine, MRR and TWR, Peak Current, Pulse on Time, Pulse off
Time, Gap Voltage.
1. Introduction
For machining purpose, now a days the most effective, advanced and efficient is electrical discharge
machining (EDM). Any material no matter it is hard or having complicated design or shape can be
machined using EDM. A lot of efforts has been put in research to analyse the effects of different
parameters on machining performance of EDM and to optimize them for different performance features.
Sanchez et al. [1] with help of a cluster of experiments, constructed an inversion model for the values
of input parameters of EDM. For prediction of performance characteristics like MRR, EWR and surface
roughness (SR), ANOVA technique and regression model were adopted for AISI 1045 steel. Aliakbari
et al. [2] used a rotary EDM process to machine X210CrNi12 alloy for different features like MRR,
EWR, SR and OC. He found that output was more affected by electrical parameters rather than by non-
electrical parameters, also on increasing the tool hole numbers, performance features like MRR, EWR
and SR increases and gives better flushing condition and to decrease TWR the tool hole number has to
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Published under licence by IOP Publishing Ltd 1
FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
reduce. Gopalakannan et al. [3] prepared a metal matrix composite of aluminium 7075 and studied the
effect of different process parameters of EDM on different performance features like MRR, EWR and
SR. He concluded that two parameters pulse current and pulse on time considerably affect the MRR
and TWR, while pulse current and pulse duration affects the SR highly. The results obtained by them
are in confirmation with optimal set following with an error of 3.21%, 6.19% and 4.63% in MRR, EWR
and SR respectively. Lin et al. [4] used Grey-Taguchi to investigate the influence of process parameters
of micro milling EDM for maching of Inconel 718 alloy. The performance features taken into
consideration were electrode wear (EW), MRR, and working gap. He shows that EW decreases, MRR
increases and working gap decreases with optimal set of process parameters of micro milling EDM.
Majumdar et al. [5] develops empirical relation between input process parameters and output, then
applied three different DMPSO techniques for optimal set of process parameters and a comparative
study was done between the above said three DMPSO techniques. He found that DMPSO-CF algorithm
gives the better optimization for EDM process parameters. Manivannan et al. [6] evaluated the optimal
set of process parameters of micro EDM for machining AISI 304 steel. L27 array of experiments were
performed cased on Taguchi. With help of TOPSIS the optimization was done for input parameters and
to identify the input given by each experiment ANOVA technique was applied. Using ANOVA he
conclude that of all process parameters, feed rate and current were the most influential. The machined
hole quality with the optimal set of parameters was analysed using SEM and results obtained were
satisfactory regarding hole quality. Marafona et al. [7] studied the effect of hardness, a surface property
on MRR and surface roughness and also the effect on EDM performance. He developed a linear
regression model working with hardness and other variables which helps in predicting MRR with an
error of 1.06% as suggested by him. He also conclude that EDM machining is also affected by material
surface hardness other than by its thermal properties. Nakalje et al. [8] used MDN 300 steel which is
having high strength and hardness for machining using EDM process. He found that discharge current,
pulse on time and pulse off time has higher influence on performance criteria like MRR, TWR, relative
wear ratio (RWR) and SR in comparison to other parameters, he also used SEM to analyse surface
roughness and he found that surface roughness is worse with higher discharge current and large pulse
time. Rahang et al. [9] done the modification on the surface of aluminium as base metal to increase its
hardness including EDM. He created a hard layer of mixture of tungsten and copper on the surface of
base metal which is aluminium as well as optimizing the different process parameters for tool wear rate
(TWR), material transfer rate (MTR), surface roughness and edge deviation. His results shows that the
hardness increases three times with respect to the hardness of base metal i.e. aluminium. Tang et al.
[10] optimize the process parameters of EDM with help if grey relational analyses and Taguchi
combined. He uses tap water as working fluid in place of conventional dielectric fluid for the sake of
health and environment as it will not produce any harmful gases and with tap water as working fluid he
obtained high MRR thus reducing the overall cost of machining. Vikas et al. [11] done experiments to
optimize the process parameters of EDM to maximize MRR for two materials EN19 and EN41. He
analysed that for any combination set of process parameters the MRR is high for EN41 with respect to
EN19, due to the fact that carbon percentage is more in EN19 and as carbon percentage increases it
becomes hard to machine which is why EN19 is not easy to machine. In this present work titanium
grade 5 alloy [Ti6al4v] is chosen for maching with help of EDM and process parameters are optimized
based on Taguchi and TOPSIS. The reason for choice of titanium grade 5 alloy is that as it is widely or
mostly used grade of titanium due to its favourable properties suited for different areas like aerospace,
medical etc. Many other researcher have also working on same area [12-17]
2. Details of experiment
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
Figure 1 shows the schematic of EDM. Electrical Discharge Machining (EDM) is a controlled metal-
departure process that is used to remove metal by strategies for electric shimmer deterioration. In this
method an electric shimmer is used as the cutting mechanical assembly to cut (deteriorate) the work-
piece to make the finished part to the perfect shape. The metal-ejection process is performed by applying
a throbbing (ON/OFF) electrical charge of high-repeat course through the anode to the work-piece. This
removes (crumbles) extraordinarily little bits of metal from the work-piece at a controlled rate. EDM
flash disintegration is equivalent to having an electrical short that consumes a little opening in a bit of
metal it contacts. With the EDM procedure both the work-piece material and the cathode material must
be conduits of power. A pre-shaped or framed anode (tool), usually produced using graphite or copper,
is moulded to the type of the hole it is to replicate. The framed anode is taken care of vertically down
and the converse state of the terminal is dissolved (consumed) into the strong work-piece. During the
EDM procedure the work-piece and the terminal are lowered in the dielectric oil (kerosene/EDM oil),
which is an electrical separator that assists with controlling the bend release. The dielectric oil, that
gives a methods for flushing, is siphoned through the circular segment hole. This evacuates suspended
particles of work-piece material and terminal from the work pit. EDM machine’s specification used in
this work is given in Table 1.
Table 1. Specifications of EDM
Designations Value
Model ZNC 50 A
Maximum Work Piece Size 800*500*325(mm*mm*mm)
Resolution 0.0005 mm
Peak Current Reach Up to 20 ampere
Gap Voltage Reach 10 to 120 volts
Pulse Duration Reach 0.3 to 550 μ-seconds
Connected Load 10 KVA
Heat Generation 12 K-Cal/Hour
Temperature to be maintained 20+/- 2°C
X,Y and Z axis travel 400,300 and 300mm respectively
Dielectric solution (DS) kerosene oil
Thermal conductivity for DS 0.158 W/m-K
Specific Heat Capacity for DS 2.2 J/g-K
Dynamic Viscosity for DS 1.56 g/m-sec
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
The material selected for machining on EDM machine and for which the performance features are
optimized is titanium grade 5 alloy [Ti6Al4V] because of its wide usage in many applications. The
work-piece taken is in cylindrical rod form whose pictorial view and its specification is shown in Figure
2 and Table 2 respectively.
In this work the tool acquired for machining of work-piece material which is also work as electrode in
EDM machining is copper cadmium electrode (Cu-Cd) which is widely being used in industries for
tooling of EDM. The tool taken is in cylindrical rod form whose pictorial view and its specification is
shown in Figure 3 and Table 3 respectively.
The four process parameters so far the literature suggested which have considerable influence on the
performance features are selected for analysis in this work and these parameters are peak current (Ip),
pulse on time (Ton), pulse off time (Toff) and gap Voltage (Vg). These four parameters which acts as
factors are selected with three different level of values for the cluster of experiments based on Taguchi.
Table 4 show the four factors with the selected level of values of these four factors.
Old style exploratory structure techniques are excessively unpredictable and are most certainly not
simple to utilize. Countless examinations must be done when the quantity of procedure parameters
increment. To take care of this issue, the Taguchi technique utilizes an extraordinary structure of
symmetrical exhibits to consider the whole parameter space with just few investigations. Orthogonal
array obtained, based on Taguchi for different selected level values is as shown in Table 5.
Table 5. Orthogonal array.
Experiment No. Factor1 Factor2 Factor3 Factor 4
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1
Taguchi test structure of analyses recommends L9 symmetrical exhibit, where 9 trials are adequate to
advance the parameters. In light of primary factor, the factors are doled out at segments, as specified by
symmetrical exhibit. The L9 array for this work with selected level values of different factors which
form the cluster for performing the experiments is as shown in Table 6.
The 9-tests were performed in the reason of the above table on the distinctive mix of factors as showed
up in table {6}. Earlier and later of each test, readings are taken for examination of MRR and TWR.
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
From above table it can be seen that the maximum MRR is obtained in experiment number 9 and
minimum TWR is obtained in experiment number 3.
4.1 Implementation of TOPSIS for decision making
The standard TOPSIS (The Technique for Order of Preference by Similarity to Ideal Solution) method
attempts to choose alternatives that simultaneously have the shortest distance from the positive idealt
solution and the farthest distance from the negative ideal solution. The positive perfect arrangement
augments the advantage measures and limits the cost models, while the negative perfect arrangemen -
amplifies the cost standards and limits the advantage rules. The initial step comprises of characterizing
the characteristics and choices. The properties are named useful (for example higher the better) or non
useful (for example bring down the better).
The Objective is to assess the 9 other options, and the traits are MRR, TWR. For this specific issue,
MRR is considered as useful quality (i.e., higher qualities); while TWR is considered as non-
advantageous (i.e., littler qualities).
4.1.1 Decision matrix
All the information of MRR and TWR is represented in form of a matrix called decision matrix as
shown below
0.00341 0.002324
0.00305 0.00103
0.00319 0.00074
0.00311 0.00175
F (n) 0.00461 0.00355
0.00416 0.00080
0.005815 0.007561
0.004635 0.002727
0.006224 0.003181
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
Overall sum of Sq. of MRR and TWR is 0.000173372 and 9.80385E-05 respectively and overall square
root of the sum of MRR and TWR are 0.013167085 and 0.009901439.
4.1.2 Normalized matrix
The measured estimations of EDM execution determination parameters are then standardized utilizing
condition given beneath.
Rij = xij / {max (xij)}, i=1 to m&j = 1 to n
0.258979114 0.234713367
0.231638211 0.104025287
0.242270785 0.074736614
0.236195028 0.176741993
0.35011546 0.358533758
0.31593933 0.08079634
0.44163154 0.763626406
0.352014134 0.275414523
0.472693844 0.321266446
The general significance of properties (Rij) can be appointed the qualities, and the loads (Wj) considered
are MRR=0.7; and TWR=0.3; the loads relegated depend on relative significance of traits, however the
aggregate of characteristics ought to be 1.
4.1.3 Weighted normalized matrix
The weighted normalized matrix is calculated using equation given below.
Vij = Rij × Wj
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
0.18128538 0.07041401
0.162146748 0.031207586
0.169589549 0.022420984
0.16533652 0.053022598
0.245080822 0.107560127
0.221157531 0.024238902
0.309142078 0.229087922
0.246409894 0.082624357
0.330885691 0.096379934
The maximum values of MRR and TWR are 0.330885691 and 0.229087922 respectively. The minimum
values of MRR and TWR are 0.162146748 and 0.022420984 respectively. Subsequent to ascertaining
the standardized framework utilizing condition (2), the following stage is to get the positive perfect
(best) and negative perfect (most noticeably awful) arrangement. These are determined utilizing
condition (3) and condition (4).
V+ = {(maxi Vij / j ɛ J) ( mini Vij | j ϵ J’| i=1, 2…..m)} ……………(3)
V- = {(mini Vij / j ɛ J) ( maxi Vij | j ϵ J’| i=1, 2…..m)} …………....(4)
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
The partition of every option from perfect arrangement is given by n-dimensional Euclidean separation.
S+i signify positive perfect detachment measure as square base of entirety of square of contrast between
positive perfect arrangement V+j and option Vij for each quality. S-i signifies negative perfect detachment
measure as square base of entirety of square of contrast between negative perfect arrangement V-j and
the option Vij for each property. The positive and negative perfect partition measures S+I and S-I are
acquired for 9 other options.
4.1.5 Relative closeness table
The relative closeness of a particular alternative to the ideal solution is calculated using equation (7).
Table 10 shows the relative closeness of each set of observations with the ideal solution.
Ci = S-I / (S+i + S- i) ……………..(7)
Table 10. Relative closeness table
C1=0.504281424 8
C2=0.539407039 6
C3=0.561810835 4
C4=0.511236038 7
C5=0.548978065 5
C6=0.660156143 2
C7=0.414301316 9
C8=0.619615130 3
C9=0.743759822 1
For every other option, relative closeness to perfect arrangement is resolved as proportion of negative
perfect detachment measure partitioned by a whole of negative perfect division measure and positive
perfect division measure. This is required to change over various reaction esteems into a solitary
presentation reaction esteem for every other option.
The relative closeness to perfect arrangement esteems are masterminded in plummeting request for all
the other options. In this way options are methodical masterminded as for ideal execution measure
which yields the best estimations of information process parameters. This relative closeness to perfect
arrangement is considered as the exhibition measure for EDM process.
5. Conclusion
It is inferred that a deliberate methodology of demonstrating and assurance of ideal or close to ideal
cutting conditions has indicated an intriguing potential with regards to both item and procedure quality
improvement of metal cutting activity, the nonexclusive structure for process parameter enhancement
in metal slicing activity endeavours to give a solitary , united and organized approach to manage choose
ideal or near ideal cutting conditions in various kinds of metal cutting technique headway issues, it
merges the use of in any event one of the current showing and smoothing out methodologies, making
the framework a bound together and convincing mean. MRR assumes a significant job in the assembling
area as it settles on the time and at last expense. The ideal blend of methodology parameters are gotten
by utilizing obvious techniques and play out the statement test for support of the outcomes. Taguchi is
utilized to get that the obligation of every parameter for overhaul of execution measures. In this work
utilizing different estimations of Current, voltage, pulse on schedule and pulse off time, considered as
info process parameters, Taguchi technique was used for maximization of MRR and minimization of
TWR and with implementation of TOPSIS technique to optimize the values of process parameters based
on the weightage provided it was found that the relative closeness of option 9 out of the 9 sets of
experiments is closest to the ideal solution so it is concluded that maximum MRR and minimum TWR
were obtained for optimal process parameters with peak current of 20 ampere, pulse on time of 100
micro seconds, pulse off time of 7 micro seconds and gap voltage of 40 volts.
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
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FSAET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1116 (2021) 012030 doi:10.1088/1757-899X/1116/1/012030
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