Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Electrical discharge machines (EDM) are widely employed in machining components containing complex profiles of hard-to-cut and materials. However, the fabrication-of-tool time for EDM process is excessively high traditional method, which significantly affects rate. Therefore, this paper, a powder metallurgy (PM) technique to fabricate tool electrode using copper (Cu), titanium carbide (TiC), zirconium silicate (ZrSiO4) different combinations. An L18 orthogonal array (OA) planned following input parameters: three types tools (Cu, Cu90, Cu80), peak current (PC) [A], pulse on (PT) [µs], gap voltage (GV) [V]. The performance evaluated through material removal rate (MRR), wear (TWR), surface roughness (SR). parameters optimized two techniques: order preference by similarity ideal solution (TOPSIS) grey relational analysis (GRA). TOPSIS GRA optimization techniques produce same optimal parametric less TWR, SR, higher MRR with combination Cu90 tool, E8 APC, 15 µs PT, 75 V GV. Based ANOVA table TOPSIS, plays major role, contributing 46.8 % performance; shows most significant contribution 39.3 values. Furthermore, scanning electron microscope (SEM) image analyses carried out machined workpiece understand effect quality.