Investigations of Process Parameters on Surface Finish of Aluminium Component Produced by Die Sink Electric Discharge Machining Process

Electric discharge machining (EDM) is one of the unconventional machining methods used to create slots, holes, and complex structures, irrespective of the hardness of the material. Die sink EDM is a productive and an economical manufacturing process that yields parts with higher grades of surface finish. Surface roughness of the component has been greatly influenced by peak current, pulse ON time and pulse OFF time. Improper combinations of these process variables will lead to decrease in surface quality. The aim of the study is to evaluate the influence of various process parameters used in die sink EDM to obtain a good surface finish in the fabricated aluminium component. Peak current, pulse on time, and pulse off time are the process parameters that have been considered for the study. Taguchi technique has been used to accomplish parameter optimization with an L9 orthogonal array, and analysis of variance has been utilized to determine the optimum parameter combination and its influence. The optimal value has been determined and it has been found that the peak current, followed by the pulse off time, and the pulse on time, have a substantial impact on the surface roughness.