The effect of rotary EDM parameters on the surface integrity and geometric parameters of holes in Si3N4-TiN electro conductive ceramics using DFA-RSM-ANN method

Silicon nitride and titanium nitride are combined to form the composite material, Syalon. This work takes an empirical look at Syalon by utilizing EDM methods with optimal settings for specific geometrical tolerances, such as cylindricity (CYLY), circularity (CIRY), and perpendicularity (PERY), low electrode wear rate (EWR), and high material removal rate (MRR). The study employs an innovative modeling approach based on integrated ANNRSM-DFA. From 0.8599 to 0.8620, the composite attractiveness ratings for different sparking process performance factors saw a substantial improvement. Results for MRR, EWR, CIRY, CYLY, and PERY were as follows: R2 = 0.7622 g/min for MRR, 0.6591 g/min for EWR, 0.6061 mm for CIRY, 0.9260 mm for CYLY, and 0.9562 mm for PERY. The response surface approach was used for the regression analysis. Determined the best neural network by looking at the correlation between predicted and actual performance measure values; the highest correlation we found was 0.92413. The globules had the tiniest dimensions of 3.511 mu m in length and 1.113 mu m2 in area. The globules had a maximum length of 24.034 mu m and an area of 7.104 mu m2, with an average length and area of about 8.3293 mu m and 2.5274 mu m2, respectively. The optimal machining conditions were used, resulting in the machined surface showing tiny globules with dimensions of 3.511 mu m in length and 1.113 mu m2 in area for the centre hole. Then, in order to determine which holes were the best and worst, the surface morphology of the machined workpiece was studied.