Effects of electrical parameters, its interaction and tool geometry in electric discharge machining of titanium grade 5 alloy with graphite tool

Abstract

In this study, the effect of electrical parameters such as current, pulse-on time, pulse-off time, their interaction, tool geometry, and cross-sectional area over the important machining responses such as metal removal rate, tool wear rate, surface roughness, and entry–exit deviation were studied while machining titanium grade 5 alloy with graphite tool electrode at negative polarity in sink electric discharge machining process. The experiment was designed with Taguchi’s L27 orthogonal array with interaction between factors. The analysis of variance was used to check the significance of parameters effect. The data obtained were analyzed with signal-to-noise ratio analysis. Residual analysis was performed to check the fitness, and a regression model had been created and validated to relate the experiment factors with the responses. The model was found to be good after experimental validation. The ranking of influence of the factors over the responses was also presented.