Analysis of EDM Process Parameters for Optimization of Overcut per Side using Taguchi Techniques

The electric discharge machining is proving as highly preferred machining process for the production of dies and molds among the tool makers. Dimensional accuracy becomes key concern when intricate geometrical profiles and shapes are required to be manufactured in components. Due to the spark erosion process, the cavity dimensions produced in the dies are larger than the tool size which results into overcut per side. The requirement is lower overcut for higher dimensional accuracy. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of dimensional deviation is essential in order to improve accuracy in designing the electrodes and arresting overcut per side. In this paper experimental investigations are carried out to study the effect of pulse current, pulse on time and gap voltage on the response of overcut per side, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining.