Investigation of Electrical Discharge Machining Efficiency with Cryogenic Copper Electrodes for AISI D2 Steel: Enhancing Material Removal Rate, Reducing Electrode Wear Rate, and Minimizing Machining Time

This work investigates the effects of cryogenic cooling on a copper electrode using electrical discharge machining on AISI D2 steel for die-sinking purposes. Within the framework of electrode machining, this research investigates how cryogenic cooling impacts material removal rate, electrode wear rate, and workpiece machining time. It conducted the investigation using an experimental design-based Taguchi L₉ orthogonal array with three factors and three levels per factor. Current (A), spark-on time (µs), and spark-off time (µs) were the machining parameters used, and the electrode wear rate, material removal rate, and machining time were the study outputs. This study investigates and explains how cryogenic cooling affects the studied reactions. Using a copper electrode and cryogenic cooling allowed for faster material removal, less electrode wear, and shorter machining times. In terms of material removal (0.42152 mm³/min), electrode wear (0.00076 mm³/min), and machining time (8.984 min), the copper electrode that was cooled using cryogenics did better than the alternatives that were not cooled using cryogenics. In summary, this study significantly influences EDM technology by illuminating the practical applications of cryogenic methods and their ability to enhance manufacturing processes for crucial applications.