Int J Adv Manuf Technol (2017) 89:897–904
DOI 10.1007/s00170-016-9130-2
ORIGINAL ARTICLE
Micro-EDM multiple parameter optimization for Cp titanium
Vijay Kumar Meena 1 & Man Singh Azad 2 & Suman Singh 1 & Narinder Singh 1
Received: 17 April 2015 / Accepted: 4 July 2016 / Published online: 13 July 2016
# Springer-Verlag London 2016
Abstract Titanium and its alloys are being employed in
various industries, e.g., aerospace, biomedical, dental, au-
tomobile, because of their very high strength, high hard-
ness, low weight, resistance to corrosion, and very low
wear rate. But its machining is always a matter of concern
due to its difficult to machine nature by conventional
means. Although electrical discharge machining (EDM)
is suitable for machining titanium and its alloys, selection
of machining parameters for higher machining rate and
accuracy is a challenging task in machining micro-holes.
The present research attempts to optimize micro-EDM pro-
cess parameters for machining commercially pure (Cp) ti-
tanium. The metal removal rate (MRR), electrode wear rate
(EWR), and overcut (OC) were chosen as observed perfor-
mance criteria to verify the optimal micro-EDM process
parameters settings. In addition, the process parameters
like current, frequency, and width (pulse on time) were
adopted for evaluation by Taguchi method-based grey re-
lational analysis.
Keywords Micro-electrical discharge machining (μ-EDM) .
Optimization . Taguchi . Grey relation analysis
* Vijay Kumar Meena
vijay.kumar.meena@gmail.com
1
Central Scientific Instruments Organisation (CSIR-CSIO),
Chandigarh, India
2
Central Mechanical Engineering Research Institute (CSIR-CMERI),
Durgapur, West Bengal, India
1 Introduction
The term “miniaturization” has lot to do with part size, feature
definition, accuracy and precision, and materials develop-
ments. This emerging technology is driving attention of
world-wide researchers and engineers in terms of micro-pro-
cesses, machines, metrology, materials, and many more as-
pects along with the development of nanoscale and micro-
scale design knowledge. Desktop machine tools, micro-
assembly systems, and miniaturized measurement systems
are now approaching towards micro-factory concept.
Micro-electrical discharge machining (μ-EDM) is the mod-
ified version of electrical discharge machining technologies
for manufacturing of micro- and miniature parts and struc-
tures. Similar to conventional EDM, material is removed by
a series of rapidly recurring electric spark discharges between
the tool electrode and the workpiece in micro-EDM. The basic
difference between micro-EDM and conventional EDM are in
the type of pulse generator, the resolution of the X-, Y-, and Z-
axes movement, and the size of the tool used. In micro-EDM,
pulse generator produces very small pulses within pulse dura-
tion of a few micro-seconds or nanoseconds. Due this reason,
micro-EDM utilizes low discharge energies (∼10−9–10−5 J) to
remove small volumes (∼0.05–500 μm3) of material [1]. The
most important factor which makes micro-EDM very impor-
tant in micro-machining is its machining ability on any type of
conductive and semi-conductive materials with high surface
accuracy irrespective of material hardness. It is preferred es-
pecially for the machining of difficult-to-cut material due to its
high efficiency and precision.
Small volumetric material removal of micro-EDM provides
substantial opportunities for manufacturing of micro-dies and
micro-structure such as micro-holes, micro-slot, and micro-
898
gears. The use of micro-EDM has many advantages in micro-
parts, the main advantage is that it can machine complex shapes
into any conductive material with very low forces. The forces
are very small because the tool and the workpiece do not come
into contact during the machining process. This property pro-
vides advantages to both the tool and the workpiece. For exam-
ple, in EDM, a very thin tool can be used because it will not be
bent by the machining force. The other advantages of micro-
EDM include low set-up cost, high aspect ratio, enhanced pre-
cision, and large design freedom. In addition, EDM does not
make direct contact between the tool electrode and workpiece
material, hence eliminating mechanical stress, chatter, and vibra-
tion problems during machining. Micro-EDM is very effective
to machine any kind of holes such as small-diameter holes down
to 10 μm and blind holes with 20 aspect ratio. Although micro-
EDM is a very efficient process in micro-hole machining and
having many advantages, it has also some disadvantages. One of
them is that it is a rather slow machining process; the other is that
while the workpiece electrode is being machined, the tool elec-
trode also wears at a rather significant rate. This tool-wear leads
to shape inaccuracies. Another drawback is the formation of a
heat-affected layer on the machined surface. Since it is impossi-
ble to remove all the molten part of the workpiece, a thin layer of
molten material remains on the workpiece surface, which re-
solidifies during cooling [2]. Physical model developed for
micro-EDM is slightly different from that of conventional
EDM. The use of resistance capacitance pulse generator, an
advanced controller for machining in smaller inter-electrode
gaps and with lower discharge energies than in EDM, makes
the material removal characteristics of a single discharge in
micro-EDM different from that of the EDM [3]. Another signif-
icant point of micro-EDM is the inverted polarity of the tool
electrode. Due to polarity effect in conventional EDM with long
pulse duration, the tool electrode is usually charged as an anode
to increase material removal rate and to reduce electrode wear.
At short pulse durations as used in micro-EDM, this effect is
reversed. Therefore, in micro-EDM, the tool electrode is usually
charged as cathode [4].
Careful selection of input parameters and their optimization
plays a great role in successful achievement of results.
Optimization of process parameters of EDM has been treated
as single-objective optimization process and multi-objective op-
timization problem. Somashekhar et al. optimized micro-EDM
input parameters for metal removal rate (MRR) using artificial
neural network [5]. Pradhan and Bhattacharyya combined re-
sponse surface methodology along with artificial neural network
for optimizing MRR, TWR, and overcut (OC) for pulse on time,
peak current, and flushing pressure for titanium alloy; effect of
polarity changing technique for micro-electrode discharge ma-
chining on Ti6Al4V for the fabrication of straight-through mi-
cro-holes was also studied [6, 7]. Muthuramalingam and Mohan
used grey relational analysis for multi-response optimization of
the electrical discharge machining for AISI 202 stainless steel
Int J Adv Manuf Technol (2017) 89:897–904
with different tool electrodes, e.g., copper, brass, and tungsten
carbide. Gap voltage, discharge current, and duty factor with
different process levels were selected as input parameters and
effect was studied on material removal rate, electrode wear rate,
and surface roughness. Copper was reported to be the best ma-
terial for EDM because of its high electrical conductivity [8].
The discharge current, pulse interval, pulse width, and gap volt-
age were optimized for EDM machining of S-03 stainless steel
using L9 orthogonal array-based grey relational analysis [9].
Prihandana et al. reported a significant increase in the material
removal rate and surface quality by suspending micro-MoS2
powder in dielectric fluid. The ultrasonic vibration was used
during micro-EDM processes and optimization was done using
Taguchi [10]. The grey relational analysis was used for optimiz-
ing feed rate, spindle speed, resistance, capacitance, and voltage
for micro-EDM hole drilling [11]. Mhatre et al. determined op-
timized levels of process parameters viz. duty cycle, pulse cur-
rent, pulse on time, electrode type, and gap voltage for output
parameters MRR, tool wear rate (TWR), and surface roughness
(SR) using grey relational analysis [12]. Experiments were con-
ducted using Taguchi L18 orthogonal array. From grey relational
analysis, the optimum values were 8 % for duty cycle (8 %),
18 A for pulse current, 200 μs of pulse on time, and voltage of
40 V. Experimental results revealed that the copper electrode
gives the optimum performance in terms of higher MRR and
lower TWR and SR. Balasubramanian and Senthilvelan used
response surface methodology for optimizing machining param-
eters in EDM process using cast and sintered copper electrodes
[13]. The selected process parameters were peak current, pulse
on time, die electric pressure, and tool diameter. The pulse cur-
rent and pulse duration were optimized for hole dilation and
taper ratio for micro-EDM hole drilling in Inconel 718 nickel-
based superalloy [14]. The study showed pulse current as more
efficient on performance characteristics than pulse duration.
Zhang et al. optimized output objectives processing time and
electrode wear by optimizing the input parameters peak current,
pulse duration, pulse off time, capacitance, electrode rotating
speed, and servo reference speed using multi-objective genetic
algorithm [15]. Meena and Azad used grey relational analysis of
Ti6Al4V alloy and reported voltage as the most significant pa-
rameter affecting output parameters MRR, TWR, and OC [16].
Central composite design with response surface approach was
used for optimizing voltage, capacitance, and feed rate of micro-
wire electrical discharge machining (micro-WEDM) for param-
eters MRR, Kerf width, and surface for Ti6Al4V alloy [17].
Tiwari et al. also used central composite design with response
surface approach to find optimized level of input parameters of
pulse on time, peak current, gap voltage, and flushing pressure
with output parameters MRR, TWR, OC, and taper for Ti6Al4V
alloy [18]. The process parameters discharge current, gap volt-
age, lifting height, negative polarity, and pulse duty factor were
optimized for electrode wear rate (EWR), MRR, and surface
roughness as objective parameters for Ti6Al4V alloy; however,
Int J Adv Manuf Technol (2017) 89:897–904
Table 1 Composition of CP-Ti
Elements C Fe H N O Ti
% composition 0.1 0.3 0.015 0.03 0.25 99.2
the dielectric used for tap water with decreased operation cost
and no harmful effects [19]. Rahman et al. used copper electrode
with positive polarity for optimizing Ti6Al4V alloy and used
response surface methodology for optimizing peak current,
pulse on time, and pulse off time levels for surface roughness
[20]. Long et al. used Taguchi method for optimizing EDM
parameters for SKD61, SKD11, and SKT4 die steels using tita-
nium powder for MRR and found that electric current, electrode
material, and powder concentration were the most significant
parameters that influenced the MRR [21]. Selvarajan et al. used
grey relational analysis for optimizing EDM parameters for im-
proving circularity, cylindricity, and perpendicularity while ma-
chining Si3N4–TiN composite [22]. A technique for order pref-
erence by similarity to ideal solution (TOPSIS) was used by
Manivannan and Kumar for multi-response optimization of
micro-EDM output process parameters, such as the material
removal rate, electrode wear rate, overcut, taper angle, and cir-
cularity at entry and exit points on AISI304 alloy [23].
In the present work, efforts are made to find the effect of
various micro-EDM input parameters on performance charac-
teristics MRR, TWR, and OC for machining of commercially
pure (Cp) titanium with tungsten carbide electrode using grey
relational analysis combined with Taguchi method-based de-
sign of experiments has been used to obtain significant pro-
cess parameters and their optimal combination level for effec-
tive micro-hole drilling in Cp titanium.
2 Experimental
The commercial pure titanium (Cp-Ti), grade 2, having thick-
ness of 1.12 mm was used for machining. The substrate was
locally purchased and the chemical composition of Cp-Ti is
Fig. 1 Sarix Sx-100 micro-EDM Milling machine
899
Fig. 2 Hole image captured
shown in Table 1. The machining was done using side flushing
technique along with electrode rotation, on high precision micro-
EDM machine, from Sarix, Model SX-100 (Fig. 1). The ma-
chine is equipped with a wire dressed unit. A Marcel-Aubert-Sa
make optical microscope (model MA-705-Z1) was used for
measurement of hole diameter. The microscope is attached on
Z-axis of the machine as shown in Fig. 2. The eroded length was
measured using the Z-axis movement of the machine and the
erosion time was noted from the MMI display of the machine.
The cylindrical tungsten carbide (WC) rod with 0.4 mm diam-
eter was used as a tool electrode and was rotated at constant
value of 200 rpm for all the experiments.
The values of other parameters viz. voltage, energy index,
gain, and gap were kept constant at 100 V, 105 (index), 80
(index), and 100 (index), respectively. The hydrocarbon oil
(HEDMA 111) having kinematic viscosity of 2.4 cSt was used
as dielectric and experiments were performed at room temper-
ature. No wear compensation was used to adjust the electrode
path accordingly to the gap and the wear. The chosen response
parameters were MRR, EWR, and OC. MRR, EWR, and OC
were determined using standard equations mentioned in re-
spective subsections. The current, pulse width, and frequency,
with three levels of each parameters, were selected as input
process parameters. The levels are shown in Table 2.
3 Design of experiment
A Taguchi method-based design of experiment has been used to
study the effect of input process parameters. All other EDM
process parameters were kept constant for all experiments. For
selecting appropriate orthogonal arrays, the degrees of freedom
Table 2 Input process parameters
Factor Levels Values Unit
Current 3 20, 35, 50 Index
Frequency 3 100, 125, 150 kHz
Pulse width 3 0.5, 1.0, 2.0 μs
900 Int J Adv Manuf Technol (2017) 89:897–904

Table 3 L9 orthogonal
array S. no. Frequency Current Width

1 150 20 0.5
2 150 50 1
3 150 35 2
4 125 20 1
5 125 50 2
6 125 35 0.5
7 100 20 2
8 100 50 0.5
9 100 35 1

of array are required to be calculated, which must be greater than

the degrees of freedom of input parameters. Degree of freedom Fig. 4 Erosion with the rod electrode to a fixed depth Z [24]
is defined as the number of fair and independent comparisons
needed for optimization of process parameters and is one less
Va
than the number of level of parameter. In this study, there are six MRR ¼ mm3 =min ð3Þ
t
degrees of freedom owing to three levels of EDM input param-
eters, so Taguchi-based L9 orthogonal array (experimental lay-
out, Table 3) was selected. Accordingly, nine experiments were
carried out to study the effect of input process micro-EDM pa- 4.2 Electrode wear rate
rameters. Figure 3 shows the image of top and bottom diameter
of machined hole. After a certain depth of erosion in micro-EDM drilling, the shape
of the rod electrode remains constant, if further drilling is per-
formed from that point down to a target depth Z (Fig. 4) [24].
4 Calculation of MRR, EWR, and OC Assumption was made that the volume of wear Ve on the
electrode is equivalent to a cylinder of diameter De (electrode
4.1 Material removal rate diameter) and length Le (eroded length from the electrode).
π 2
The average volume of material removed over the machining Ve ¼ De Le ð4Þ
time was used for calculating MRR, which is expressed as 4
cubic millimeters per minute. Ve
π TWR ¼ mm3 =min ð5Þ
V a ¼ Da 2 h ð1Þ t
4
For a given depth Z, Le can be measured on the machine
where Da is average diameter of hole drilled and h is the using a reference plane. After each drilling operation, the elec-
thickness of the workpiece. trode tip is brought to the reference plane. The measurement
Dtop þ Dbottom value along the Z-axis before and after machining determines
Da ¼ ð2Þ
2 the loss of an electrode length Le [24].

Fig. 3 Top and bottom diameters

of the machined hole
Int J Adv Manuf Technol (2017) 89:897–904 901

grade is obtained by averaging the grey relational coeffi-

cients corresponding to each performance characteristic.
The highest grey relational grade corresponds to the best
optimal level of experiments.
In this study, the data sequence for MRR is pre-processed
as follows:
x0i ðk Þ−min x0i ðk Þ
x*i ðk Þ ¼ ð7Þ
max x0i ðk Þ−min x0i ðk Þ

EWR and OC are pre-processed as follows:

maxx0i ðk Þ− x0i ðk Þ
x*i ðk Þ ¼ ð8Þ
max x0i ðk Þ−min x0i ðk Þ
Fig. 5 Schematic of overcut
where
4.3 Overcut x*i ðk Þ is the value after grey relational generation;
min x0i ðk Þ is the smallest value of x0i ðk Þ;
The schematic of overcut of the micro-holes is shown in Fig. 5
max x0i ðk Þ is the largest value of x0i ðk Þ.
and can be measured using
The grey relational coefficient [ξi(k)] can be calculated as
Da−De follows:
OC ¼ mm ð6Þ
2
Where Da is the average diameter of the hole after machin- Δmin þ ς Δmax
ξ i ðk Þ ¼ ð9Þ
ing, and De is the diameter of the electrode. Δ0i ðk Þ þ ς Δmax

where
x*0 ðk Þ denotes the reference sequence;
5 Grey relational analysis x*j ðk Þ denotes the comparability sequence;
ς ∈ [0 − 1] is the distinguishing coefficient, 0.5 is widely
In grey relational analysis, data pre-processing is the ini- accepted;


tial step and is carried because the units and target direc- Δ0i ¼
x*0 ðk Þ−x*i ðk Þ
is the difference in absolute value
tion of one data sequence, i.e., experimental result of out- between x*0 ðk Þ and x*i ðk Þ;



put parameter may differ from that of others, e.g., the unit


Δmin ¼ min min
x*0 ðk Þ−x*j ðk Þ
is the smallest value of
of MRR and EWR is cubic millimeters per minute where- ∀ j∈i ∀k
as for overcut is millimeter. During this step, the output Δ0i;






parameters are normalized in the range between zero and Δmax ¼ max max
x*0 ðk Þ−x*j ðk Þ
is the largest value of
one. Grey relational coefficient is calculated from the nor- ∀ j∈i ∀k

malized experimental data in the next step. Grey relational Δ0i.

Table 4 Experimental and pre-

processed results S. no. Experimental results Pre-processed results

MRR (mm3/min) EWR (mm3/min) OC (mm) MRR EWR OC

1 0.015977 0.008866 0.08925 1 0 0

2 0.011266 0.008594 0.05875 0.522385 0.060222 0.60696517
3 0.010288 0.006711 0.0595 0.423283 0.476663 0.5920398
4 0.006427 0.007732 0.039 0.03187 0.250895 1
5 0.007085 0.006995 0.0485 0.09859 0.413905 0.81094527
6 0.006113 0.00614 0.0415 0 0.603183 0.95024876
7 0.00672 0.00683 0.0515 0.061578 0.450396 0.75124378
8 0.009677 0.007465 0.06175 0.361271 0.309871 0.54726368
9 0.006292 0.004346 0.065 0.018163 1 0.48258706
902 Int J Adv Manuf Technol (2017) 89:897–904

Table 5 Grey relational

coefficients, grey grade, and order S. no. Grey relational coefficients Grey grade Order

MRR EWR OC

1 1 0.333333333 0.333333333 0.555555556 4

2 0.511448571 0.347275856 0.559888579 0.472871002 8
3 0.464374733 0.488597498 0.550684932 0.501219054 6
4 0.340569373 0.400286451 1 0.580285275 3
5 0.356783517 0.460364933 0.725631769 0.514260073 5
6 0.333333333 0.557527388 0.909502262 0.600120995 2
7 0.347603207 0.476369995 0.667774086 0.497249096 7
8 0.439085982 0.420122646 0.524804178 0.461337602 9
9 0.337419032 1 0.491442543 0.609620525 1

After calculating grey relational coefficients, the grey rela-

Table 6 Effect of EDM machining parameters on grey relational grade tional grade is obtained as
n
Parameter Grey relational grade Max − min 1X
γi ¼ ξ ðk Þ ð10Þ
Level 1 Level 2 Level 3
n k¼1 i

Frequency 0.522735741 0.564888781a 0.509881871 0.05500691 where γi is the grey relational grade and n is the number of
Current 0.544363309 0.570320191a 0.482822892 0.087497299 performance characteristics. Table 4 shows the experimental
Pulse 0.539004717 0.554258934a 0.504242741 0.050016193 and data pre-processed results. Table 5 shows the grey rela-
width tional coefficients and corresponding grey relational grade for
each experiment.
Mean value of grey relational grade, 0.064173
a
Among nine experiments, the experiment no. 9 has the
Optimal level of parameter
highest grey relational grade, and the level of parameters in

Fig. 6 Effect of input parameters

Int J Adv Manuf Technol (2017) 89:897–904
Table 7 Grey relational grade obtained with optimized parameters
Input parameter setting Grey relational grade
Frequency 100 kHz 0.60962
Current 35
Pulse width 1 μs
Frequency 125 kHz 0.69281
Current 35
Pulse width 1 μs
Improvement in grey 0.08319
relational grade
the experiment no. 9 (frequency 100 kHz, current 35, pulse
width 1 μs) are closest to the best performance of micro-EDM
hole drilling in Cp-Ti. Further, it is possible to find out the
optimal set and their effects on selected output parameters.
Table 6 shows the mean of grey relational grades of all param-
eters at different levels as well as the difference between the
maximum and minimum value of the grey relational grade of
the EDM machining parameters, which shows the importance
of individual factor in EDM machining.
The highest grey relational grade shows the optimal level
of parameter viz; frequency 125 kHz, current 35, and pulse
width 1 μs, for the better performance of micro-EDM drilling.
Importance of the EDM machining parameters are in the fol-
lowing order: current, frequency, pulse width. Figure 6 shows
the effect of parameters on grey relational grade.
6 Verification experiment
Verification experiment was performed using optimized set of
parameters, i.e., frequency 125 kHz, current 35, and pulse
width 1 μs. The values obtained for MRR, TWR and OC were
0.006495 mm3/min, 0.005959 mm3/min and 0.048 mm, re-
spectively. These values were used again for normalization,
grey relation coefficient and grey relational grade calculation.
The relational grade got improved by 0.08319 with optimized
parameter settings (Table 7).
7 Conclusion
Micro-electrical discharge machining process is a widely used
micro-fabrication technique for the production of micro-parts
and micro-features, finding application in micro-mechatronic
systems, automobile, surgical tools, etc. Its low cost of oper-
ation and ability to machine any conductive material irrespec-
tive of its hardness is one of the reasons for its popularity in
micro-machining processes and is discussed extensively
among researchers. The micro-hole drilling in Cp titanium
903
and optimization of input parameters, i.e., current, frequency,
and pulse width, are the primary aims of the present study. The
effect of input parameters on output parameters, i.e., material
removal rate, electrode wear rate, and overcut was studied.
Based on the study performed, the following conclusion
may be drawn:
a. Micro-EDM process has enough potential for generating
micro-features in commercially pure titanium, which is
very difficult to machine by conventional tool-based mi-
cro-operation like micro-drilling and micro-milling.
b. Current is the most influential parameter among current,
frequency, and pulse width for micro-EDM machining of
commercially pure titanium.
c. Grey relational analysis can be effectively utilized in si-
multaneous optimization of parameters for getting the de-
sired results. Accuracy of results depends on the effective
setting of parameters.
Acknowledgments The authors acknowledge the financial support re-
ceived from the Council of Scientific and Industrial Research (CSIR),
New Delhi, for its network project “BIOCERAM,” under its XIIth Five
Year Plan.
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