Statistical investigations into the erosion of material from the tool in micro-electrical discharge machining

This paper presents a statistical study of the erosion of material from the tool electrode in a micro-electrical discharge machining process. The work involves analysis of variance and analysis of means approaches on the results of the tool electrode wear rate obtained based on design of experiments approach. The input factors used in the experiments are discharge current (Id), discharge frequency (fd), and pulse width (wp). The individual effects as well as interactions among the input factors have been considered for the analysis. The results of this investigation show that discharge current (Id) and discharge frequency (fd) control the erosion of material from the tool electrode. The material erosion from the tool electrode (Me) increases linearly with the discharge frequency. As the current index increases from 20 to 35, the Me decreases linearly by 29%, and then increases by of 36%. The current index of 35 gives the minimum material erosion from the tool. It is observed that none of the two-factor interactions are significant in controlling the erosion of the material from the tool.