Experimental Investigations of Hole - EDM to Optimize Electrode Wear through Full Factorial of Design of Experiment

Abstract

Electrical discharge machining (EDM) is a process where the material removal of theworkpiece is achieved through high frequency sparks between the tool (electrode) and theworkpiece immersed into the dielectric solution. It is commonly used to produce mouldsand dies, to drill small, burr free holes and to make prototypes for the aerospace andelectronics markets. In this work, micro-holeswere fabricated on copper alloys by usingEDM. The output responses investigated was electrode wear weight (EWW). Fullfactorial of Design of Experiment (DOE) module in Minitab was used as a principalmethodology to examine the effects of current and machining time over output responses.Experimental results indicate that the EWW was mainly affected by current, and can bereduced by increasing the current parameter. Minimum EWW (0.12gm) obtained at 10A.