Electrical discharge machining (EDM) is a potent technique widely applied to machining
materials like EN-8M steel and composite materials. The surface quality achieved through
EDM is significantly affected by the settings of its parameters and the type of material
being processed. In this context, the focus of research has often been on heavy metals and
titanium and magnesium alloys among lighter metals. This study aims to investigate the
impact of EDM parameters, specifically on Tungsten Carbide, a material gaining traction
across various industries. Our research involved a thorough parametric analysis utilizing
a full factorial method to examine factors influencing surface roughness (SR) and material
removal rate (MRR). This paper highlights the optimization of MRR using a Rotary electrode
attachment. Experiments were conducted employing factorial design to delve deeper into the
machining characteristics of Tungsten Carbide with a 4 mm Brass-coated rod as the electrode.
Key parameters such as summit current, electrode rotation speed, and Pulse on time were
systematically adjusted. The analysis of the machining parameters revealed their significant
influence on the outcomes, with p-values falling below 0.05, underscoring their critical role
in the EDM process. The developed mathematical models demonstrated a high R-squared
value alongside minimal error percentages. The most critical parameters identified for optimal
results included an electrode rotational speed of 150 rpm, a summit current of 1.22 A, and
a Pulse on time set at 8.45 ms. |
