DOI: 10.36347/sjet

Pages: 447-462

The objective of research is to study the influence of Process parameters and electrode shape configuration on the Machining characteristics of die sinking EDM. The present work aims to study the effect of different electrode shapes (Circular, rectangular and triangular) With constant cross sectional area of 280 mm2 on material removal rate (MRR), surface roughness (SR) and Electrode wear rate (EWR) for AISI 316 Stainless steel workpiece material and pure copper As electrode material. Detailed analysis of structural features of machined surface is done by using Scanning Electron Microscope (SEM) to understand the mode of heat affected zone (HAZ), recast layer thickness and micro cracks which alternatively affects structure of machined workpiece and hence tool life. The optimization of the parameters of the EDM machining will be carried out by using the taguchi‟s method for design of experiments (DOE). The main objective of this analysis is to identify the Optimum electrode shapes in terms of higher MRR, minimum EWR and excellent surface characteristics. The optimum tool shape for higher MRR, lower EWR and excellent SR is circular, followed by rectangular and Triangular cross sections.