The Optimization of Micro-Edm Machining Process when Using Carbon Coated Micro Electrode as a Tool
More details
Hide details
Department of Mechanical Engineering,, Hung Yen University of Technology and Education, Viet Nam
Department of Mechanical Engineering, Rajararambapu Institute of Technology, India
Submission date: 2023-03-28
Final revision date: 2023-05-02
Acceptance date: 2023-05-05
Online publication date: 2023-05-07
Publication date: 2023-06-12
Corresponding author
Bich Thi Mac   

Department of Mechanical Engineering, Hung Yen University of Technology and Education, Viet Nam
Journal of Machine Engineering 2023;23(2):186–197
The amount of electrode wear in micro-EDM has a direct effect on the dimensional accuracy of the machined hole. Therefore, improving the corrosion resistance of electrodes in micro-EDM is still of great interest. The effective coating of thin film for the micro tool electrodes in the case of micro-EDM can lead to minimize the electrode wear which eventually improve the productivity and machining quality. In the present study, experiments were performed on micro-EDM using carbon coated tool electrode and optimized using Taguchi-Topsis to investigate optimum levels of Depth of cut (Z) and overcut (OVC). It was concluded that optimum conditions had improved significantly using carbon coated micro tool electrode. Optimal levels of technological parameters include V = 160 V, C = 10000 pF, RPM = 600 rpm, and Zopt = 2.525 mm, OVCopt = 65.257 m. The quality of the machined surface with the coated electrode at optimal conditions is analysed and evaluated. The Topsis method is a suitable solution to this problem, and the steps to perform the calculation in this technique are simple.
ABLYAZ T., MURATOV K., PREETKANWAL S.B., SARABJEET S.S., 2019, Experimental Investigation of Wear Resistance of Copper Coated Electrode-Tool During Electrical Discharge Machining. IOP Conf. Ser.: Mater. Sci. Eng., 510, 012001,
MANDAL P., MONDAL S.C., 2021, Performance Analysis of Copper-Based MWCNT Composite Coated 316L SS Tool in Electro Discharge Machining, Mach. Sci. Technol., 25, 422–437, 2020.1855652.
KARUNAKARAN K., CHANDRASEKARAN M., 2017, Investigation of Machine-Ability of Inconel 800 in EDM with Coated Electrode, IOP Conf. Series: Materials Science and Engineering, 183, 012014. doi:10.1088/1757-899X/183/1/012014.
CHIOU A.H., TSAO C.C., HSU C.Y., 2015, A Study of the Machining Characteristics of Micro EDM Milling and its Improvement by Electrode Coating, Int. J. Adv. Manuf. Technol. 78, 1857–1864 /s00170-014-6778-3.
SHIRGUPPIKAR S.S., PATIL M.S., 2020, Experimental Investigation on Micro-Electro Discharge Machining Process Using Tungsten Carbide and Titanium Nitride-Coated Micro-Tool Electrode for Machining of Ti-6Al-4V, Advances in Materials and Processing Technologies, 8/1,
HUANG C.H., YANG A.B., HSU C.Y., 2018, The Optimization of Micro EDM Milling of Ti–6Al–4V Using a Grey Taguchi Method and its Improvement by Electrode Coating, Int. J. Adv. Manuf. Technol., 96, 3851–3859,
LIU, Y., WANG W., ZHANG W., MA F., YANG D., SHA Z., ZHANG S., 2019, Experimental Study on Electrode Wear of Diamond-Nickel Coated Electrode in EDM Small Hole Machining, Advances in Materials Science and Engineering, 7181237,
CHINDALADDHA N., KAEWDOOK D., 2020, Performance of Electroplated Copper Coating on Graphite Electrode in EDM Process, TNI Journal of Engineering and Technology, 8/1, 50–57.
PRASANNA J., RAJAMANICKAM S., 2016, Investigation of Die Sinking Electrical Discharge Machining of Ti-6Al-4V Using Copper and Al O -Tio Coated Copper Electrode, Middle-East Journal of Scientific Research, 24 (S1), 33–37,
YUANGANG W., FULING Z., JIN W., 2009, Wear-Resist Electrodes for Micro-EDM, Chinese J. Aeronaut. 22, 339–342,
REOLON L.W., LAURINDO, C.A.H, TORRES R.D., et al. 2019, WEDM Performance and Surface Integrity of Inconel Alloy IN718 with Coated and Uncoated Wires, Int. J. Adv. Manuf. Technol., 100, 1981–1991,
PANCHAL S.K., BIRADAR V.Y., GOSAVI D.L., 2016, Analysis of EDM Process Parameters by Using Coated Electrodes, International Journal of Engineering Trends and Technology 4/4, IJETT-V41P234.
HANIZAM H., MOHAMAD N., AZLAN U.A.A., QAMARUDDIN M., 2017, Process Optimization of EDM Cutting Process on Tool Steel using Zinc Coated Electrode, MATEC Web of Conferences, 97, 01073,
GEORGE J., CHANDAN R., MANU R., MATHEW J., 2021, Experimental Investigation of Silicon Powder Mixed EDM Using Graphene and CNT Nano Particle Coated Electrodes, Silicon 13, 3835–3851, 10.1007/s12633-020-00658-0.
UHLMANN E., ROSIWAL S., BAYERLEIN K., RÖHNER M., 2010, Influence of Grain Size on the Wear Behavior of CVD Diamond Coatings in Micro-EDM, Int. J. Adv. Manuf. Technol., 7, 919–922, 10.1007/s00170-009-2131-7.
PHAN N.H., van DONG P., DUNG H.T. et al., 2021, Multi-Object Optimization of EDM by Taguchi-DEAR Method Using Alcrni Coated Electrode, Int. J. Adv. Manuf. Technol. 116, 1429–1435, s00170-021-07032-3.
ALAVI F., JAHAN M.P., 2017, Optimization of Process Parameters in Micro-EDM of Ti-6Al-4V Based on Full Factorial Design, Int. J. Adv. Manuf. Technol., 92, 167–187,
HSU H.Y., HU C.C., 2017, Surface Quality Improvement of Edmed Ti–6Al–4V Alloy Using Plasma Etching and Tin Coating, Int. J. Adv. Manuf. Technol. 88, 67–74,
BARAL S.K., PALLAVI P., UTKARSHAA A., 2021, Effect of Nichroloy Coated Electrode on Machining Performance of Electrical Discharge Machining Using Inconel 625, Materials Today: Proceedings, 45, 7894–7900,
PHAN N.H., et al. 2021, Tool Wear Rate Analysis of Uncoated and Alcrni Coated Aluminum Electrode in EDM For Ti-6Al-4 V Titanium Alloy, Sattler, KU., Nguyen, D.C., Vu, N.P., Long, B.T., Puta, H. (eds) Advances in Engineering Research and Application, ICERA 2020, Lecture Notes in Networks and Systems, 178, Springer, Cham,
PHAN N.H., et al. 2021, Material Removal Rate in Electric Discharge Machining with Aluminum Tool Electrode for Ti-6Al-4V Titanium Alloy, Sattler, KU., Nguyen, D.C., Vu, N.P., Long, B.T., Puta, H. (eds) Advances in Engineering Research and Application, ICERA 2020, Lecture Notes in Networks and Systems, 178, Springer, Cham,
BINAYAKA N., 2017, A Review on Optimization of Micro EDM Machining Performances, International Journal of Engineering Research, 6/5, 242–246,
SINGH N., BHARTI P.S., 2022, Multi-Objective Parametric Optimization During Micro-EDM Drilling of Ti-6Al-4 V Using Teaching Learning Based Optimization Algorithm, Materials Today: Proceedings, 62/1, 262–269,
PARTHIBAN M., HARINATH M., 2021, Optimization of Micro-EDM Drilling on Titanium Alloy (Ti-6AL-4V) Using RSM and Neural Network, Journal of Physics: Conference Series 2070, 012223, 17426596/2070/1/012223.
ILANI M.A., KHOSHNEVISAN M., 2020, Powder Mixed-Electrical Discharge Machining (EDM) with the Electrode is Made by Fused Deposition Modeling (FDM) At Ti-6Al-4V Machining Procedure, Multiscale and Multidiscip. Model. Exp. and Des. 3, 173–186,
PONAPPA K., SASIKUMAR K.S.K., SAMBATHKUMAR M., UDHAYAKUMAR M., 2019, Multi-Objective Optimization of EDM Process Parameters for Machining of Hybrid Aluminum Metal Matrix Composites (C/Tic/B4C) Using Genetic Algorithm, Surface Review and Letters, 26/10, 1950071, S0218625X19500719.
KOLLI M., PRASAD A.V.S.R., NARESH D.S., 2021, Multi-Objective Optimization of AAJM Process Parameters for Cutting of B4C/Gr Particles Reinforced Al 7075 Composites Using RSM-TOPSIS Approach, SN Appl. Sci. 3, 711,
PHAN N.H., DONG P.V., DUNG H.T., Nguyen Van THIEN N.V., et al., 2021, Multi-object optimization of EDM by Taguchi-DEAR method using AlCrNi coated electrode, Int. J. Adv. Manuf. Technol. 116, 1429–1435.
HUU P.N., MUTHURAMALINGAM T., VAN D.P., et al., 2022, Multi-Objects Optimization in µ-EDM Using AlCrNi-Coated Tungsten Carbide Electrode for Ti-6AL-4 V, Int. J. Adv. Manuf. Technol. 122, 2267–2276,
NGUYEN P.H., BANH T.L., MASHOOD K.A., et al., 2020, Application of TGRA-Based Optimisation for Machinability of High-Chromium Tool Steel in the EDM Process, Arab. J. Sci. Eng., 45, 5555–5562,
SIVA M., ARUNKUMAR N., SUBRAMANIAN M., ELAKKIYADASAN R., 2022, Influence of Micro-Electrical Discharge Machining Parameters on the Surface Morphology of the Nickel-Coated Electrode, Materials and Manufacturing Processes, Materials and Manufacturing Processes, 38/1, 2022.2105869.
TAHERKHANI A., ILANI M.A., EBRAHIMI F., et al., 2021., Investigation of Surface Quality in Cost of Goods Manufactured (COGM) Method of Μ-Al2O3 Powder-Mixed-EDM Process on Machining of Ti-6Al-4V, Int. J. Adv. Manuf. Technol. 116, 1783–1799,
ILANI M.A., KHOSHNEVISAN M., 2022, An Evaluation of the Surface Integrity and Corrosion Behavior of Ti-6Al-4 V Processed Thermodynamically by PM-EDM Criteria, Int. J. Adv. Manuf. Technol. 120, 5117–5129,