INVESTIGATION OF THE EFFECT OF PULSES CYCLE TIME AND ELECTRODE MATERIAL ON THE OVER CUT DURING THE ELECTRICAL DISCHARGE MACHINING PROCESS

Through the Electrical Discharge Machining, temperature is very high, which affects material properties and process responses, and can lead to failure of the products in industry. This study aims to cover three points, firstly to investigate the effect of new input parameter (pulses cycle time Tc), with other parameters on the over cut (OC), the prediction model is developed. Second point assessing the effect of using Silver-Tungsten electrode and Cupper-Tungsten electrode on OC, during machining of powdered metallurgical high speed steel which is very important material in industry, such as aerospace, automotive, and electrical power industries, it is used in structural components, heat exchangers. Third point utilizing an integrated approach combines Response surface design and Genetic Algorithm optimization methodology for modeling and optimizing the response. Two software's Minitab software and Matlab software were utilized for this purpose. Experimental results demonstrated comparative findings when Silver-Tungsten electrode and Genetic Algorithms method were used. Optimized values of the responses were as following: optimized value of over cut was 0.049mm, optimization percentage was 30%.