Influence of energy distribution and process parameters on tool wear in electrical discharge machining

In the present scenario, the complex shapes of moulds and dies is being fabricated using electrical discharge machining process. Since the tool wear affects the surface quality of the machined specimens, it is very important to enhance the tool electrode machinability in such machining process. In the present study, an attempt has been made to analyze the influence of energy distribution on tool wear rate and surface roughness of machined AISI 202 stainless steel with different pulse generators such as transistor pulse generator and iso energy pulse generator. The experimental investigation has been done under L₉ Taguchi orthogonal array with various process parameter selection as open circuit voltage, peak current and duty factor. Brass electrode has been utilized as the tool electrode to investigate the performance measures such as tool wear rate and surface roughness of machined workpiece. From the experimental results, it has been observed that iso energy pulse has produced 13.1 % less tool wear with good surface quality. It has also been observed that open circuit voltage has most significant nature on determining tool wear rate.