Optimization of Material Removal Rate in EDM Of D2 Steel by Taguchi Method

Material removal rate is an important aspect in any machining process as it decides the time taken to complete machining. This becomes more important in unconventional machining where material removal rate is much lower compared to traditional machining.The present study has been on optimization of MRR with the help of Taguchi method through a case study in Electric Discharge Machining (EDM) of D2 Steel. Any electrically conducted material can be machined in EDM. But D2 steel finds extensive application in die making. Dies are often of complicated shape and EDM is the best suited machining operation to meet such demand. Due to this in the experiment D2 steel has been used as a workpiece. D2 steel is also tough and has greater strength as well as very good wear resistant. Two conventional electrodes Copper, Brass and a special electrode created by Direct Metal Laser Sintering have been considered as tools for performing the experiments. Special DMLS electrode has been chosen along with conventional electrode to assess the feasibility of substituting these conventional electrodes by the special electrode. Confirmatory test is carried out to validate the effectiveness of the process