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<p>Among the most effective unconventional machining techniques for cutting materials that are hard to machine is EDM. Modern EDM equipment enables the machining of components with complex shapes and those made from difficult-to-machine materials. However, two major challenges persist even with heat-treated tool steels, composites, superalloys, and ceramics: high tool wear and a slow material removal rate. With a focus on electrode wear rate (EWR) and material removal rate (MRR) during M2 tool steel machining, the current study aims to experimentally examine the effects of cryogenic treatment on copper electrodes in EDM. The M2 tool steel utilized in the experiment has a maximum hardness of 62 HRC. With dimensions of 12&#xa0;mm in diameter and 100&#xa0;mm in length, it was manufactured utilizing three different kinds of electrode materials: untreated copper, cryogenically treated copper, and cryogenically treated and tempered copper. In accordance with a L9 orthogonal array design, three levels of EDM various Process parameters were applied, like pulse-off time (s), pulse-on time (s), and discharge current (A). In the second part of the study, Grey-Taguchi analysis was used to improve output parameters including MRR and EWR during the EDM process on M2 tool steel. The findings suggest that by selecting the ideal electrode and process parameters to optimize MRR, deepen cut, and minimize tool wear, the EDM process may be made more effective and function better overall.</p>

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Experimental Analysis of Process Parameters in Electric Discharge Machining of M2 Tool Steel Using Cryogenic-Treated and Untreated Copper Electrodes: A Taguchi Approach

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Mudda Nirish,
  • Pentamaraju Madhavi

摘要

Among the most effective unconventional machining techniques for cutting materials that are hard to machine is EDM. Modern EDM equipment enables the machining of components with complex shapes and those made from difficult-to-machine materials. However, two major challenges persist even with heat-treated tool steels, composites, superalloys, and ceramics: high tool wear and a slow material removal rate. With a focus on electrode wear rate (EWR) and material removal rate (MRR) during M2 tool steel machining, the current study aims to experimentally examine the effects of cryogenic treatment on copper electrodes in EDM. The M2 tool steel utilized in the experiment has a maximum hardness of 62 HRC. With dimensions of 12 mm in diameter and 100 mm in length, it was manufactured utilizing three different kinds of electrode materials: untreated copper, cryogenically treated copper, and cryogenically treated and tempered copper. In accordance with a L9 orthogonal array design, three levels of EDM various Process parameters were applied, like pulse-off time (s), pulse-on time (s), and discharge current (A). In the second part of the study, Grey-Taguchi analysis was used to improve output parameters including MRR and EWR during the EDM process on M2 tool steel. The findings suggest that by selecting the ideal electrode and process parameters to optimize MRR, deepen cut, and minimize tool wear, the EDM process may be made more effective and function better overall.