Examination of the effect of process parameters on surface integrity in processing mirrax mold steel with the electro erosion method

In this thesis study, the effects of different electrode materials (CuCoNiBe, CuNi₂SiCr, and CuCr₁Zr) and machining parameters (discharge current, pulse-on time, and pulse-off time) on the machined surface were investigated within the scope of the Electrical Discharge Machining (EDM) process. The experimental study was conducted based on the Taguchi L27 experimental design, and analyses were carried out focusing on the machining outcomes of overcut and surface crack density (SCD). The experimental results revealed that the most favorable outcomes in terms of overcut were obtained using the CuCoNiBe electrode in combination with a low discharge current (6 A), short pulse-on time (50 µs), and medium pulse-off time (200 µs). According to ANOVA analysis, the most influential parameters on the overcut were determined as discharge current (31.77%) and pulse-on time (16.88%). In terms of SCD, the lowest crack density was achieved using the CuCoNiBe electrode with high discharge current (25 A), short pulse-on time (50 µs), and long pulse-off time (800 µs). Electrode type emerged as the most dominant factor affecting SCD, with a contribution ratio of 58.97%. In this context, the CuCoNiBe electrode material stands out as a recommended alternative for EDM applications. The findings serve as a guide for achieving high-quality surfaces in industrial applications and lay a foundation for future studies.