In present days non-conventional machining process plays a tremendous role in manufacturing industries. To achieve the highly accurate, finished product with good quality and to make the intricate shapes, non-conventional machining like electrical discharge machining (EDM) is used to withstand the competition and to meet the demands in the industry. In electro-thermal non-traditional (or) un-conventional machining process, EDM is one where electrical sparks are generated by creating voltage difference between the electrode and work piece and due to the thermal electric energy of the sparks; the eroding of material takes place. To machine the materials which are difficult to machine in traditional machining and for temperature resistant high strength alloys EDM is applicable. The practical applications include dies in watches, mould cavity with deeper and narrow slots, mould cavity for the injection molding. In present study Martensitic stainless steel (SS) 420 is used to conduct the experiment by varying the control factors such as Discharge current (Ip), Pulse on time (Ton) and Duty cycle (%). Process responses such as material removal rate (MRR) and surface roughness (SR) are determined for every experimental run. With a minimum amount of experimentation Taguchi’s L9 orthogonal array (OA) is used to study the response of control factors with varying levels. A mathematical and statistical technique called Response surface methodology (RSM) has been used for the analysis and modeling of the MRR and SR by using the commercial tool Design expert 18.104.22.168.
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Author Name: P. Sree lakshmi, Dr. B.E Kumar
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Keywords: EDM, SS 420, L9 OA, RSM, MRR and SR