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The current research aims at analyzing the machining performance measures of titanium diamond using electro-discharge machining (EDM) process. The selected control variables are peak current and pulse-on-time (Ton) while maintaining a 50% to 75% duty factor during experimental runs. The output responses considered for this operation are material removal rate (MRR), tool wear rate (TWR) and average surface roughness (Ra). A full factorial design (L16) has been employed to execute the current investigation. Analysis of variance along with overall evaluation criteria (OEC) is also carried out for determining the optimal input parametric combination. The work is further supported by mean effect plots and 3D performance plots for visual illustration of outputs. Analyzed results show that current has the most impact on MRR and Ra, while Ton has the most impact on TWR. The obtained results show MRR of 7.753 mg/min (highest), TWR of 0.02 mg/min (lowest) and Ra of 5.46 µm at the optimum parametric combination. Moreover, x-ray diffraction (XRD), scanning electron micrograph (SEM), and energy-dispersive x-ray (EDX) analysis also help in identifying different phases of material on machined work surface.

Machinability characteristics of titanium diamond using EDM and its parametric optimization