Machining and optimization of Zircaloy-2 using different tool electrodes

Abstract

To explore machining parameters for tool wear rate, surface roughness, and material removal rate, Zircaloy-2 was machined with EDM using Cu, CuW and graphite tool. Taguchi L18 Design was used to perform experiments with five independent process parameters (tool material, on-time, off-time, polarity, and current). Response parameters were evaluated and optimized using gray relation analysis and entropy-integrated-gray-VIKOR methods. FESEM was used to observe tool material and oxide layer deposition on machined surface. Maximum material removal rate (1.53 × 10−3 mm3/min) was obtained when the graphite tool with negative tool polarity was used. A confirmation test performed on the optimal factor level process parameters gives an error of 1.9%, 6.4%, and 9.8% for TWR, SR, and MRR respectively.