Multi-Response Optimization of Rotary Electrode EDM Process Parameters for Tungsten Carbide

Electrical discharge machining (EDM) is a potent technique widely applied to machining materials like EN-8M steel and composite materials. The surface quality achieved through EDM is significantly affected by the settings of its parameters and the type of material being processed. In this context, the focus of research has often been on heavy metals and titanium and magnesium alloys among lighter metals. This study aims to investigate the impact of EDM parameters, specifically on Tungsten Carbide, a material gaining traction across various industries. Our research involved a thorough parametric analysis utilizing a full factorial method to examine factors influencing surface roughness (SR) and material removal rate (MRR). This paper highlights the optimization of MRR using a Rotary electrode attachment. Experiments were conducted employing factorial design to delve deeper into the machining characteristics of Tungsten Carbide with a 4 mm Brass-coated rod as the electrode. Key parameters such as summit current, electrode rotation speed, and Pulse on time were systematically adjusted. The analysis of the machining parameters revealed their significant influence on the outcomes, with p-values falling below 0.05, underscoring their critical role in the EDM process. The developed mathematical models demonstrated a high R-squared value alongside minimal error percentages. The most critical parameters identified for optimal results included an electrode rotational speed of 150 rpm, a summit current of 1.22 A, and a Pulse on time set at 8.45 ms.