Black layer affects the thermal conductivity of the surface of copper-tungsten electrode

The aim of this article is to show that the black layer composition varies with an interaction of electrical discharge machining (EDM) input parameters, which affects the electrode wear ratio (EWR), using the Taguchi methodology. An orthogonal array that provides a countermeasure to interactions was used. The analysis seeks the optimal levels of the EDM input parameters that produce an improvement in the EWR. The additive model was used with the optimum levels of the parameters to predict the EWR values. The outcome analysis shows a poor confirmation, meaning that there is an interaction of EDM input parameters affecting the EWR values. Thus, the present investigation reveals that black layer affects the electrode wear ratio due to a change in the thermal conductivity of the surface of copper-tungsten electrode.