Reducing the geometrical machining errors incurred during die repair and maintenance through electric discharge machining (EDM)

Abstract The importance of geometrical accuracy can never be overruled in dies and molds which governs the dimensional precision parts being manufactured. continuous use such tooling requires repair maintenance. Among different processes used to upkeep consistency tooling, machining is essentially required most cases. intricacy molds’ cavities electric discharge (EDM). However, EDM it challenging develop control over machined dimensions owing inherent issues overcut/undercut. This aspect was not comprehensively investigated so far core focus this research. Three electrode materials, namely, copper, graphite, tungsten carbide, belong category metals, nonmetals, ceramics, respectively, have been compared for said perspective on comprehensive list parametric variables. results revealed that average value axial errors 2.5 times lesser comparison lateral errors. In case errors, graphite has proved a promising choice other two types copper carbide. noticed appealing option reducing error (A.E). mean A.E obtained with Cu 80.9% 47.6% lower than achieved respectively. Furthermore, optimal combination based 7 variables also proposed using desirability analyses whose validity during confirmation trials.