Multi-variable optimization in die-sinking EDM process of AISI420 stainless steel

Die-Sink Electric Discharge Machining (DS-EDM) is a preferred advanced method, used to produce the complex geometry, cavities, die, and mold facing difficult in cutting the materials. In the current research work, machining of AISI420 stainless steel with copper electrode has been performed. Gap voltage (V), Pulse current (A), and Pulse on time (T) are considered as machine control variables (MCV) and material removal rate (MRR) and electrode wear rate (EWR) as measured machining performance. Experiments have been designed with the assistance of the Taguchi technique and further, Taguchi-Grey Relational Analysis (T-GRA) is executed to optimize the MCV. Parametric analysis is carried out to observe the implications of MCV on the measured machining performance. After interpretation the observations, it has been analyzed that the factors A, V, and T influenced 63.71%, 13.26%, and 10.88%, respectively, on the optimal explication. The fittest method positions have been confirmed by conducting a validation test. It has been explicitly proved that multiple performance characteristics in the DS-EDM method have been considerably enhanced by the T-GRA technique. The rise in grey relational grade is 0.086 by using the T-GRA technique.