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Abstract

This article demonstrates that the Sinker Electrical Discharge Machining (S-EDM) method can be enhanced using SPHC (JIS G 3131) materials with a hardened surface. During S-EDM, neither contact nor a cutting force exists between the electrode and the work piece. S-EDM is advantageous because it eliminates mechanical stress, chatter, and vibration issues with traditional milling. S-EDM is widely employed, for example, in the manufacturing of molds for automotive and aviation components. Taguchi design and signal-to-noise ratio (S/N ratio) were selected to examine the impact of the input parameter model on the Material Removal Rate (MRR). The Taguchi approach assessed three input parameters and three experimental levels. The parameters of pulse current (I), spark time (Ton), and gap voltage (Vg) were chosen to evaluate the MRR performance of the S-EDM process with the SPHC-hardened work piece material.Copper with a diameter of 10 mm is chosen as the electrode material. This study aims to determine the optimal MRR for the chosen input variables. Results indicate that a more effective pulse current value promotes debris removal from the machining zone and stabilizes following spark release, speeding the Material Removal Rate (MRR). In the S-EDM machining process, the pulse current value significantly affects the MRR. It is one of the most significant response variables, followed by spark on time and gap voltage, with delta values of 4.64, 2.71 and 1.13, respectively. The Taguchi experiment has been successfully implemented and achieved the maximum MRR at 38.97, a pulse current of 16 A, a spark on time of 400 µs, and a gap voltage of 45 volts.