Experimental Analysis and Optimization of EDM Parameters on HcHcr Steel in Context with Different Electrodes and Dielectric Fluids Using Hybrid Taguchi-Based PCA-Utility and CRITIC-Utility Approaches

Industries demand stringent requirements towards economical machining without hindering the surface quality while cutting high carbon chromium (HcHcr) steel. Electrical discharge (EDM) of HcHcr steel aims at reducing cost (i.e., maximize material removal rate (MRR) and minimize tool wear (TWR)) with good roughness (SR)). A comparative study was carried out on EDM D2 (DIN EN ISO 4957) by applying Taguchi L18 experimental design considering different electrode materials (copper, graphite, brass), dielectric fluids (distilled water kerosene), peak current, pulse-on-time. The process performances were analyzed respect to rate, roughness, rate. Pareto analysis variance employed estimate significance variables their optimal levels for achieving lower SR TWR higher MRR. Hybrid Taguchi-CRITIC-Utility Taguchi-PCA-Utility methods implemented determine parameters. Higher MRR 0.0632 g/min 1.68 µm 0.012 attained graphite in presence distilled as fluid compared brass copper. Additionally, a metallographic integrity machined surfaces. Micrographic conditions showed fewer imperfections (lesser impression, waviness surface, micro-cracks) worst conditions.