Optimization of machining parameters in sinking electrical discharge machine of caldie plastic mold tool steel

The aim of this study was to investigate the machinability of caldie cold work tool steel using the electro erosion technique. In the experimental study, graphite and copper were used as the electrode materials. Three levels for discharge current (6, 12 and 25 A) and three levels for pulse duration (50, 100 and 200 µs) were used as machining parameters. The experimental model was designed according to the Taguchi L18 orthogonal array. Signal/noise ratios, graphs and regression analysis were used to evaluate the results of the experiments. Using the Taguchi technique, the optimum machining parameters were determined with process outputs for surface roughness, material removal rate and electrode wear rate. The optimum levels were found to be A1B1C1 for surface roughness and electrode wear rate and A2B3C3 for material removal rate. The effect of control factors on experimental outputs was calculated by performing ANOVA. According to the ANOVA results, discharge current was the most effective parameter on machinability. When the experimental data were compared statistically with the Taguchi optimization and regression model data, the results of the designed models were shown to be successful.