Study on material removal rate, surface quality, and residual stress of AISI D2 tool steel in electrical discharge machining in presence of ultrasonic vibration effect

Electrical discharge turning is an emerging modification of die sinking electrical discharge machining process that enables to machine the difficult-to-cut round cylindrical bars. In the present study, the machinability of AISI D2 workpiece was studied while the tool electrode has high-frequency longitudinal vibration. Here, a series of experiments has been carried out taking into account the effect of ultrasonic power, spindle speed, discharge current, pulse on time, and pulse off time to study material removal rate (MRR), surface roughness (Ra), and residual stress (RS). The process has been studied through Taguchi orthogonal design through conducting of 27 experiments. Analysis of variances has also been carried out to find which factor has the greatest effect on process performance. Results indicated that among the factors, pulse current and workpiece rotation have the greatest effect on MRR and SR while the pulse on time is most influential on RS.