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<p>The investigation in this study pertains to the multi-objective optimization of a cryogenically treated tool electrode utilized in electrical discharge machining (EDM). A copper beryllium alloy underwent both mild and extensive cryogenic treatment processes. Subsequently, the untreated alloy, as well as the mildly and extensively treated copper beryllium alloys, were employed as electrode materials. The work piece material utilized was AISI 4140 stainless steel. The EDM process was conducted through die-sinking EDM. The optimization of various input parameters (amperes current, duty factor and electrode material) to enhance material removal rate (MRR), tool wear rate (TWR), and surface roughness was achieved through Taguchi–Grey relational analysis. Upon analysis, it was determined that under the selected input conditions, 3 amperes current, 40% duty factor, and an extensively treated electrode had yielded the most optimized response. Following a confirmation test, a 0.6% enhancement in the predicted Grey relational grade was observed.</p>

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Multi-variable optimization of cryogenically treated copper beryllium tool electrodes for electrical discharge machining

  • 期刊论文

  • 发表日期：

    2026年3月23日

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  • M Pervaz Ahmed,
  • H Siddhi Jailani,
  • C K Arvinda Pandian,
  • J Mahashar Ali

摘要

The investigation in this study pertains to the multi-objective optimization of a cryogenically treated tool electrode utilized in electrical discharge machining (EDM). A copper beryllium alloy underwent both mild and extensive cryogenic treatment processes. Subsequently, the untreated alloy, as well as the mildly and extensively treated copper beryllium alloys, were employed as electrode materials. The work piece material utilized was AISI 4140 stainless steel. The EDM process was conducted through die-sinking EDM. The optimization of various input parameters (amperes current, duty factor and electrode material) to enhance material removal rate (MRR), tool wear rate (TWR), and surface roughness was achieved through Taguchi–Grey relational analysis. Upon analysis, it was determined that under the selected input conditions, 3 amperes current, 40% duty factor, and an extensively treated electrode had yielded the most optimized response. Following a confirmation test, a 0.6% enhancement in the predicted Grey relational grade was observed.