Optimizing micro-EDM with carbon-coated electrodes: A multi-criteria approach

The pursuit of precision machining in engineering materials has ignited an imperative to advance electrical discharge machining (EDM) techniques. This study is a deep dive into the domain of micro-electrical discharge machining (mu EDM) with a specific focus on the utilization of carbon-coated tool electrodes. The primary objective is to elucidate the influence of carbon-coated electrodes on vital machining parameters, including machining depth (Z coordinate), tool wear rate (TWR) and overcut (OC) in mu EDM operations. Moreover, the investigation extends to scrutinizing surface characteristics generated by mu EDM with carbon-coated tool electrodes. To enhance performance, carbon-coated tungsten carbide tool electrodes are employed for machining titanium alloy (Ti-6Al-4V) workpieces. The optimization process seeks to identify the optimal combination of process parameters using a Taguchi-DEAR-based multi-response approach. Experimental findings reveal that integrating carbon-coated electrodes significantly improves the mu EDM process, leading to enhanced surface performance metrics. Notably, this study identifies specific parameter settings that effectively optimize machining quality indicators. By achieving a voltage of 160V, a capacitance of 10,000pF and a tool rotation of 600RPM, the research contributes valuable insights into the intricate realm of mu EDM, highlighting the potential for enhanced surface performance through strategic parameter manipulation.