Title: Optimisation of surface integrity model using response surface methodology for EDMed AISI D2 tool steel

Authors: M.K. Pradhan; C.K. Biswas

Addresses: Department of Mechanical Engineering, Maulana Azad National Institute of Technology, Bhopal, 462051, India. ' Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769 008, India

Abstract: In this analysis, the influence of machining parameters, i.e., pulse current (Ip), pulse duration (Ton), duty cycle (Tau) and discharge voltage (V) on the surface roughness (Ra), surface crack density (SCD) and white layer thickness (WLT) of surface created in electrical discharge machining are examined. Experiments were carried out on AISI D2 steel work-piece materials using face centred central composite design. Applying the composite desirability function method, the optimal-setting of the parameters was obtained with a reduced number of experiments that needed to provide sufficient information for statistically acceptable results. Further, to make out the desirability region the overlaid contour plots were presented. The minimal condition for WLT, Ra and SCD were found to be a pulse current of 3 A, a pulse duration of 50 µs, a duty cycle of 80% and discharge voltage 40 volt. Under such optimum conditions, it was observed experimentally minimisation of the said responses.

Keywords: electrical discharge machining; EDM; white layer thickness; WLT; surface roughness; surface crack density; SCD; response surface methodology; RSM; tool steel; desirability function; central composite design; CCD; electro-discharge machining; surface quality; surface integrity.

DOI: 10.1504/IJMMS.2012.049967

International Journal of Mechatronics and Manufacturing Systems, 2012 Vol.5 No.5/6, pp.340 - 360

Received: 11 May 2011
Accepted: 23 Oct 2011
Published online: 21 Aug 2014 *

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