Improving Sustainability of EDM Sector by Implementing Unconventional Competitive Manufacturing Approach

Abstract

In this research work, an attempt was made to machine the titanium (Ti6Al4V) alloy utilizing electric discharge machining technique. The distinct process parameters and its impact on the machining performance were identified using the cause-and-effect diagram (CED). The key process parameters identified by CED diagram were current, pulse on time (Ton), aluminium oxide (Al2O3) powder concentration, and gap distance; experiments were conducted by varying the process parameters, experimental runs were designed using the Taguchi mixed orthogonal array. The experimental results revealed that improvement in material removal rate (MRR) was due to the bridging effect; reduction in tool wear rate (TWR) owing to the expansion of spark gap and enhancement in the surface roughness (Ra) was due to the complete flushing of machined debris. The interaction impact was analysed using the contour plot and with the aid of mathematical modelling experimental fits that were identified and the results were validated utilizing the sensitivity analysis. The obtained results were optimized using the technique for order of preference by similarity to ideal solution (TOPSIS) optimization technique.