LAUSR

ABSTRACT Electrical discharge machining (EDM) is one of the most accepted machining processes in the precision manufacturing industry. In EDM process, finding an alternative tool material is the demand in modern manufacturing industry. Therefore, an attempt had been made to fabricate copper–titanium diboride powder metallurgy electrode to test in EDM on monel 400™ material. The experiments are planned using center composite second-order rotatable design and the model is developed by response surface methodology. The machining characteristics have analyzed using the developed model. In this study, four input parameters such as titanium diboride percentage, pulse current, pulse on time, and flushing pressure are selected to evaluate the material removal rate (MRR) and tool wear rate (TWR). The adequacy of the developed regression model has tested through analysis of variance test. The desirability-based multiobjective optimization is used to find the optimal process parameter which has given maximum MRR and minimum TWR. The optimum process parameters obtained were titanium diboride of 16%, pulse current of 6 A, flushing pressure of 1 Mpa, and pulse on time of 35 µs. The validity of the response surface model is further verified by conducting confirmation experiments.