Performance study of EDM process parameters using TiC/ZrSiO [sub] 4 particulate-reinforced copper composite electrode

Saminatharaja, Duraisivam (author), Suresh, Periyakgounder (author), Selvaraj, Mahalingam (author), Elangandhi, Jamuna (author)

Electrical discharge machines (EDM) are widely employed in machining components containing complex profiles of hard-to-cut and machining materials. However, the fabrication-of-tool time for the EDM process is excessively high in the traditional machining method, which significantly affects the machining rate. Therefore, in this paper, a powder metallurgy (PM) technique is employed to fabricate the tool electrode using copper (Cu), titanium carbide (TiC), and zirconium silicate (ZrSiO4) for different combinations. An L18 orthogonal array (OA) is planned using the following input parameters: three types of tools (Cu, Cu90, Cu80), peak current (PC) [A], pulse on time (PT) [µs], and gap voltage (GV) [V]. The performance of EDM is evaluated through the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The process parameters are optimized using two different techniques: the technique for order of preference by similarity to the ideal solution (TOPSIS) and grey relational analysis (GRA). TOPSIS and GRA optimization techniques produce the same optimal parametric solution for less TWR, SR, and higher MRR with the combination of the Cu90 tool, E8 APC, 15 µs pulse PT, and 75 V GV. Based on the ANOVA table of TOPSIS, pulse on time plays a major role, contributing 46.8 % of the machining performance; peak current shows the most significant contribution of 39.3 % of the machining performance using GRA values. Furthermore, the scanning electron microscope (SEM) image analyses are carried out on the machined workpiece surface to understand the effect of tools on machining quality.

• Language: English
• Keywords: powder metallurgy, composite tool, copper, electrical discharge machine, technique for order of preference by similarity to ideal solution, grey relational analysis
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2021
• Number of pages: Str. 547-556
• Numbering: Vol. 67, no. 11
• PID: 20.500.12556/RUL-133579
• UDC: 621.9.048:669.3
• ISSN on article: 0039-2480
• DOI: 10.5545/sv-jme.2021.7254
• COBISS.SI-ID: 87277827
• Publication date in RUL: 02.12.2021

Record is a part of a journal

• Title: Strojniški vestnik
• Shortened title: Stroj. vestn.
• Publisher: Zveza strojnih inženirjev in tehnikov Slovenije [etc.], = Association of Mechanical Engineers and Technicians of Slovenia [etc.
• ISSN: 0039-2480
• COBISS.SI-ID: 762116

Secondary language

• Language: Slovenian
• Title: Študija zmogljivosti procesa EDM z elektrodo iz kompozita bakra in ojačitvenih delcev TiC/ZrSiO [sub] 4
• Keywords: prašna metalurgija, kompozitno orodje, baker, EDM, TOPSIS, GRA