Optimizing the process parameters for Powder metallurgy electrode in Electrical Discharge Machining

Abstract This paper presents a novel approach for the optimization of process parameters on new powder metallurgy electrode in Electrical Discharge Machining with multiple responses based on comparing Data Envelopment Analysis based Rank Method. These two methods have a series of steps from of proposed approach which are capable of decreasing uncertainty caused by engineering judgment in the Taguchi method. Experiments are conducted by varying the Electrical Discharge Machining parameters related to metallurgy powder proportion, current and pulse on time and optimized with the considerations of multi responses such as material removal rate (MRR) and Tool Wear Rate. Three factors and three levels were taken to conduct the experiments with the range 6–10% for proportion of powder in the combination of Copper with Titanium Carbide and Copper with Tungsten Carbide, current 3–9 A and pulse on time from 150 to 450 µs. The two methods show a good convergence with the experimental data and the optimum process parameters combinations where maximum material removal rate (MRR) and minimum tool wear rate are obtained.