Metallurgical Approach Towards Explaining Optimized EDM Process Parameters for Better Surface Integrity of AISI D2 Tool Steel

Many attempts have been made to model and optimize performance parameters of Electrical Discharge Machining (EDM) process. In this investigation, the experimental design includes L9 orthogonal array based on the Taguchi methodology. The corresponding effect of input current, duty cycle and spark on time, on surface integrity, has been studied on AISI D2 tool steel. The residual stress measurement is done using X-ray diffraction method. The obtained output results regarding material removal rate, surface roughness, crack density, and residual stress have been modeled and optimized by regression equation and Genetic algorithm respectively. In this investigation, a metallurgical approach has been introduced towards the explanation of the resulted optimized response parameters.