Published Paper Details:

In the present days of competitive world, the industries are trying to meet the market demand and increase the profits with optimal costs of the products being manufactured. Machining of hard metals, complex shapes with traditional manufacturing is difficult and it also results in extreme tool wear and damage of workpiece material. To overcome such drawbacks, unconventional machining processes such as Electric Discharge Machining (EDM) can be used to machine hard metals. In this project a prototype model of Die-Sinking EDM set-up is used consisting of different modules namely, pulse generation and control unit, tool-feed control unit. Square holes are machined on Zinc and Copper workpieces with Stainless Steel tool of size 9mm2 by using deionized water as dielectric fluid under different machining conditions by varying control factors like voltage and duty cycle. These experiments are carried out based on Taguchi�s Design of Experiments and Grey Relational Analysis is used for the optimization. An attempt has been made in this paper to investigate the optimal combination of process parameters, voltage, duty cycle.