Optimization of electrodischarge machining parameters on ZrO2 ceramic using the Taguchi method

Abstract

The purpose of the present investigation was to optimize the electrodischarge machining (EDM) parameters for machining ZrO2 ceramic. During the EDM process, the surface of the electrically non-conductive ceramic was covered with adhesive conductive copper and aluminium foils to attain the threshold of electrical conductivity for the EDM process. The machining characteristics associated with the EDM process such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR) were explored through the experimental study according to an L18 orthogonal array based on the Taguchi experimental design method. Analysis of variance was conducted to examine the significant machining parameters affecting the machining characteristics. The experimental results show that peak current and pulse duration significantly affected MRR and SR, and the adhesive conductive material was the significant parameter correlated with EWR. In addition, the optimal combination levels of machining parameters were also determined from the response graph of signal-to-noise ratios for each level of machining parameters. The aim of the study was to establish a feasible process and optimize the parameter levels for processing electrically non-conductive ceramics through EDM. A practical and convenient process for shaping electrically non-conductive ceramics was developed in the present work with the features of high efficiency, high precision, and excellent surface integrity.