Optimization of processing parameters in electro erosion machining of DIN 1.2344 steel

Many materials cannot be machined by classical machining methods due to their complex geometry and high hardness. In such cases, the electro-erosion machining method is widely used. However, in this method, both poor surface quality and high machining times create serious problems. In this study, DIN 1.2344 steel, which is widely used in mold making, was machined by electro-erosion method. Cutting parameters have been optimized to determine the most suitable surface quality and the lowest machining times. Pure copper electrodes with a diameter of 12 mm were used in the experiments. Taguchi L18 experiment list was created by using 3 different cutting parameters. In order to determine the most efficient parameters in machining, the average roughness (Ra) values of the machined surfaces, metal removal rate (MRR) and electrode wear rate (EWR) were measured. Signal-to-noise ratios of the measured values were calculated using the Taguchi method. The smallest-best method was used because Ra and EWR desired the smallest value, and the largest-best method was used because the largest value was desired for MRR. Optimum parameters were determined according to the signal-to-noise ratios. Ampere was the most effective parameter for Ra, MRR and EWR. According to the ANOVA results, the confidence level of the experimental study was approximately 93% for Ra, 92% for MRR, and 78% for EWR. Finally, the mathematical model for Ra, MRR and EWR was derived by regression analysis.