Optimization and Prediction of Material Removing Rate in Die Sinking Electro Discharge Machining of EN45 Steel Tool

The main aim of this paper is to maximization of MRR in die sinking electro-discharge machining of EN45 material using Taguchi method. EN45 is a manganese spring steel with high carbon content. EN45 is used widely in the motor vehicle industry for leaf springs, truncated conical springs, helical springs and spring plates and many general engineering applications. MRR (Material Removal Rate) is the measure of material removal and is determined by evaluating the difference of initial weight of work piece to final weight of work piece and dividing by machining time. MRR is major factor in machining process and generally it decides the machining time. Considering the current short product life cycle, maximum MRR is always desirable. Therefore parameters affecting the MRR should be recognized and optimized for desire results. The experiments conducted based on the L27 Orthogonal array and results were optimized. Experiment were carried out using four input parameters viz. peak current (Ip), pulse on time (Ton), pulse off time (Toff) and voltage (V) with three different levels. The effects of different input parameters and effect of their combination on MRR determined using Taguchi and ANOVA table. It was observed that peak current and pulse off time are more significant factor for MRR. (C) 2015 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing and Characterization.