PARAMETRIC OPTIMIZATION OF NEAR DRY ELECTRICAL DISCHARGE MACHINING PROCESS FOR AISI SAE D-2 TOOL STEEL

Present dissertation work has attemptedto optimize the various significant process parameters for near dry EDM processby Taguchi method and design of experiments. The response variables arematerial removal rate (MRR), the surface roughness (SR) and tool wear rate(TWR). A low cost mist delivery system (MQL fluid dispenser) to supply the mist(liquid-gas mixture) at a controlled rate has been developed to conduct theexperiments and has served it’s purpose exceptionally well during theexperimentation. The AISI SAE D-2 tool steel has been used as a work-piecematerial. The kerosene air mixture has been used as a dielectric medium. Thevarious process parameters selected for the study were discharge current, gapvoltage, pulse on time, duty factor, air pressure and electrode material. Astandard L18 orthogonal array was selected fordesign of experiments.