Optimization of Machining Parameters in Electrical Discharge Machining of Steel Using Taguchi Method

  • Unique Paper ID: 170571
  • PageNo: 468-474
  • Abstract:
  • This study explores the influence of key electrical discharge machining (EDM) parameters—discharge current, pulse-on time (Ton), pulse-off time (Toff), and dielectric pressure—on the machining performance of stainless steel using a flat base copper tool. Material removal rate (MRR) and surface roughness (SR) were analyzed as output responses, with experiments designed using an L18 orthogonal array and validated through Analysis of Variance (ANOVA). The results reveal that discharge current and Ton significantly affect both MRR and SR. Higher discharge currents increase spark intensity, leading to elevated temperatures that enhance material removal through melting and vaporization, but also result in rougher surface textures. Conversely, increasing Ton reduces MRR due to the expansion of the plasma channel, while contributing to higher SR owing to extended heat application. Dielectric pressure aids in clearing debris from the machining zone, thereby improving process stability, though its direct impact on MRR and SR is less pronounced. Toff was observed to have minimal influence on both responses. These findings highlight the importance of optimizing discharge current and Ton to balance efficiency and surface quality, ensuring reliable machining performance. The insights gained provide valuable guidance for enhancing EDM processes in industrial applications.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{170571,
        author = {Qamran Jamal and Randeep Singh},
        title = {Optimization of Machining Parameters in Electrical Discharge Machining of Steel Using Taguchi Method},
        journal = {International Journal of Innovative Research in Technology},
        year = {2024},
        volume = {11},
        number = {7},
        pages = {468-474},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=170571},
        abstract = {This study explores the influence of key electrical discharge machining (EDM) parameters—discharge current, pulse-on time (Ton), pulse-off time (Toff), and dielectric pressure—on the machining performance of stainless steel using a flat base copper tool. Material removal rate (MRR) and surface roughness (SR) were analyzed as output responses, with experiments designed using an L18 orthogonal array and validated through Analysis of Variance (ANOVA). The results reveal that discharge current and Ton significantly affect both MRR and SR. Higher discharge currents increase spark intensity, leading to elevated temperatures that enhance material removal through melting and vaporization, but also result in rougher surface textures. Conversely, increasing Ton reduces MRR due to the expansion of the plasma channel, while contributing to higher SR owing to extended heat application. Dielectric pressure aids in clearing debris from the machining zone, thereby improving process stability, though its direct impact on MRR and SR is less pronounced. Toff was observed to have minimal influence on both responses. These findings highlight the importance of optimizing discharge current and Ton to balance efficiency and surface quality, ensuring reliable machining performance. The insights gained provide valuable guidance for enhancing EDM processes in industrial applications.},
        keywords = {Electric Discharge machining; Material Removal rate; Surface roughness; ANOVA.},
        month = {December},
        }

Cite This Article

Jamal, Q., & Singh, R. (2024). Optimization of Machining Parameters in Electrical Discharge Machining of Steel Using Taguchi Method. International Journal of Innovative Research in Technology (IJIRT), 11(7), 468–474.

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