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Multi-optimization method for new design of angled electrodes and performance enhancement using alloy steel (X210)

Abbas Ahmed Mohammed, Khleif Ali Abbar

Management Systems in Production Engineering

2024

nr 3 (32)

438--449

Electrical Discharge Machining (EDM) process is considered as one of the ultimate famously process used in the components production like tools of surgical, dies, punch and aerospace. The EDM technique perform on the control of loss metal principle according to power as thermal-electric through the electrode and blank piece. Alloy steel (X210) was selected as a workpiece, whereas copper electrodes selected by in different angled electrodes (0°, 22.5°, 45°, 67.5°, and 90°). The technique of composite design (CCD) was applied in this work and accomplish (ANOVA) was concluded to consider the highly important variables. The experimental results show that the material removal rate is accelerate at highest value using Angle of Electrode (E A 67.5°) and (I 30A). Electrode Wear Rate (EWR) can be attained using (E A 22.5°) and (I 20A).Thickness of White Layer (WLT) is increased at (E A 22.5°) with enlarge current at maximum magnitude (30 A), minimize WLT is obviously at (E A 45°) and current is (15A). An optimization technique was utilize to conclude of optimal parameters at maximize MRR and consequently reduce EWR. The optimum values for the responses such as MRR and EWR with optimum value are gained with the following parameters: (E A 22.5°), (I 27), (P-on299) and (P-off 50).