Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 30840
Optimization of Control Parameters for MRR in Injection Flushing Type of EDM on Stainless Steel 304 Workpiece

Authors: M. S. Reza, M. Hamdi, A.S. Hadi


The operating control parameters of injection flushing type of electrical discharge machining process on stainless steel 304 workpiece with copper tools are being optimized according to its individual machining characteristic i.e. material removal rate (MRR). Lower MRR during EDM machining process may decrease its- machining productivity. Hence, the quality characteristic for MRR is set to higher-the-better to achieve the optimum machining productivity. Taguchi method has been used for the construction, layout and analysis of the experiment for each of the machining characteristic for the MRR. The use of Taguchi method in the experiment saves a lot of time and cost of preparing and machining the experiment samples. Therefore, an L18 Orthogonal array which was the fundamental component in the statistical design of experiments has been used to plan the experiments and Analysis of Variance (ANOVA) is used to determine the optimum machining parameters for this machining characteristic. The control parameters selected for this optimization experiments are polarity, pulse on duration, discharge current, discharge voltage, machining depth, machining diameter and dielectric liquid pressure. The result had shown that the higher the discharge voltage, the higher will be the MRR.

Keywords: ANOVA, EDM, MRR, Injection Flushing, Stainless Steel 304, L18 OrthogonalArray

Digital Object Identifier (DOI):

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1486


[1] Can Cogun (2006). An experimental investigation of tool wear in electric discharge machining, Int J Adv Manuf Technol 27 488-500.
[2] Daniel D. Frey (1973). A Role for "One-Factor- at-a-Time" Experimentation In Parameter Design, Journal of the American Statistical Association 68. 353-360.
[3] EDM hand book/
[4] E.S. Pearson (1972) Tables for statisticians, Biometrika 2 178.
[5] Gunawan S.P. (2006). Effect of vibrated electrode in electrical discharge machining, Proceedings of the 1st International Conference & 7th AUN/SEED-Net Fieldwise Seminar on Manufacturing and Material Processing 14-15 March 2006, Kuala Lumpur, pp. 133-138 (ISBN:983-42876-0-7).
[6] Handbook FINE Sodick, Vol. 1.1. Machining Condition Parameter Setting & Jigs/Tools and Flushing.
[7] Huang H. (2003). Ultrasonic vibration assisted electro-discharge machining of microholes in Nitinol, J. Micromech. Microeng. 13. 693-700.
[8] Jiju Antony (2001). Teaching the Taguchi method to industrial engineers, Work Study Volume 50 Number 4. pp. 141-149, MCB University Press ISSN 0043-8022.
[9] Lee C.M. (2006). A study on the optimal cutting condition of a high speed feeding type laser cutting machine by using Taguchi method, International Journal of Precision Engineering and Manufacturing Vol. 7. No.1.
[10] Lee H.T. (2003). Relationship between EDM parameters and surface crack formation, Journal of Materials Processing Technology 142. 676-683.
[11] Lin C.L. (2002). Optimisation of the EDM Process Based on the Orthogonal Array with Fuzzy Logic and Grey Relational Analysis Method", Int J. Adv Manuf Technol 19. 271-277.
[12] Nicolo Belavendram (2005), Student Notes, Robust Design, KCEC 4301 Semester 1 Department of Design and Manufacturing, Faculty of Engineering, University of Malaya.
[13] Scott et al. (1991). Analysis and optimization of parameter combination in wire electrical discharge, Int. J. Prod. Res. 29. 2189- 2207.
[14] Shanker Singh et al. (2004). Some investigations into the electric discharge machining of hardened tool steel using different electrode materials, J. Mater. Process. Technol., 149. 272-277.
[15] Shinya Hayakawa (2004). Study on EDM phenomena with in-process measurement of gap distance, J. of Processing Technology 149. 250- 255.
[16] Vaani T. (2005). Optimization of Control Parameters in Electric Discharge Machining of Hardened Tool Steel with Copper Electroplated Aluminium Electrodes, International Conference on Recent Advances in Mechanical & Materials Engineering, Paper No. 110.
[17] Wang C.C. (1999). The machining characteristics of Al2O3/6061 Al composite using rotary electro-discharge machining with a tube electrode, J. of Materials Processing Technology 95. 222-231.
[18] Wang C.C. (2000). Blind-hole drilling of Al2O3/6061 Al composite using rotary electro-discharge machining, J. of Materials Processing Technology 102. 90-102.
[19] X.P. Li (2001). Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide, J. of Materials Processing Technology 115. 344- 358.
[20] Yan B.H. (2000). Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite, International Journal of Machine Tools & Manufacture 40. 1403- 1421.