Selection of Process Parameters and Their Machine Levels for Electro-discharge Face Grinding of D2 Steel

Electro-discharge face grinding (EDFG) has been progressed as a hybrid unconventional machining process for grinding of difficult-to-cut materials. The EDFG process utilizes a rotating grinding tool which provides the grinding as well as spark erosion action to cause the material removal from the workpiece. In the current research work, the experimental study has been performed to study the effect of input process parameters including discharge current, pulse-on time and tool wheel speed on material removal rate (MRR) and average surface roughness (ASR) with the aim to choose their appropriate levels while machining of D2 steel. Experiments were conducted for one-factor-at-a-time design, and the optimum values for levels of process parameters were selected by graphical analysis. Finally, the parameters having a significant effect on process performance were evaluated.