Multi-Objective Optimization of PMEDM Process of 90CrSi Alloy Steel for Minimum Electrode Wear Rate and Maximum Material Removal Rate with Silicon Carbide Powder

Abstract

This study aims to minimize electrode wear (EW) and maximize material removal rate (MRR) in powder mixed electrical discharge machining (PMEDM) process of 9CrSi alloy steel with silicon carbide powder. To achieve these objectives, Taguchi method and Grey Relational Analysis (GRA) are applied to optimize one two-level and four three-level PMEDM process parameters, including T on , T off , CP, IP and SV in eighteen experiments based on an orthogonal array L 18 (2 1 and 4 3 ). Results have provided a set of optimal PMEDM process parameters in which T on has the strongest effect on SW and MRR while that of CP is insignificant. The obtained minimum EW and maximum MRR have been verified and proven by a PMEDM experiment using optimal process parameters. The proposed method can be further applied to optimize other PMEDM process parameters for different objectives.