Optimization of MRR, TWR and surface roughness of EDMed D2 Steel using an integrated approach of RSM, GRA and Entropy measutement method

In this research, a hybrid optimization approach is proposed for the determination of the optimal process parameters that maximizes the material removal rate, minimize surface roughness & the tool wear rate. Three input parameters namely pulse current (Ip), pulse duration (Ton) & pulse off time (Toff) of electrical discharge machining were considered for this analysis. The experiments were planned as per response surface methodology and subsequently gray relational analysis has been used to optimize the aforesaid response and finally the weight of the responses was determined by the entropy measurement method. Analysis of variance is used to find the effect of input parameters on the responses and found that Ton was the most influencing parameter followed by Ip and Toff in EDM of D2 steel. The R2 value for the grey relational grade model was 0.919. These results provide useful information about how to control the responses and ensure higher productivity, high-accuracy and higher surfaces-quality surfaces. This method is simple with easy operability. The assessment outcome provides a scientific reference to obtain the minimal condition of surface integrity, and they were found to be a pulse current of 5A, pulse duration of 60 μs, and pause time of 45 μs.