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Experiments and optimization of the hole EDM electrode’s parameters

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Abstract

Hole EDM process parameters are extensively addressed, but electrode design variables have not been optimized to boost output objectives. This investigation optimizes electrode parameters, including the tool rotational speed (S), water pressure (P), electrode length (L), and internal diameter (ID) to enhance the machined gap (MG), hole conicity (HC), noise emission (NE), particulate pollution (PP), and power factor coefficient (PFC) of the Ti6Al4V. The method based on the removal effects of criteria and multi-attributive border approximation area comparison is utilized to select weights and optimality. A novel model of the process sustainable index (PSI) is comprehensively proposed to evaluate the deployment of the EDM operation. The radial basis function interpolation models were proposed and applied to forecast the response outcomes. The findings presented that the optimal S, P, L, and ID were 200 rpm, 80 kg/cm2, 340 mm, and 0.6 mm, respectively. The enhancements in the MG, HC, NE, PP, and PFC were 58.2%, 44.1%, 24.2%, 12.0%, and 10.7%, respectively. Quality indicators were primarily affected by the electrode length and internal diameter, while ecological indices significantly were influenced by the tool rotational speed and water pressure, respectively. The optimality could be applied in the practical hole EDM for saving costs and efforts.

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Data Availability

All data and materials have been included in the manuscript.

Abbreviations

S :

rpm

 Tool rotational speed

HC :

Hole conicity

ID :

mm

 Internal diameter

L :

mm

 Electrode length

MG :

μm

 Machined gap

NE :

dB

 Noise emission

P :

kg/cm2

 Water pressure

PFC :

Power factor coefficient

PP :

μg/m3

 Particulate pollution

PSI :

Process sustainable index

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Funding

This research is funded by Le Quy Don Technical University.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Le Quy Don Technical University, 236 Hoang Quoc Viet, Ha Noi, 100000, Vietnam

    Trung-Thanh Nguyen

  2. Faculty of Engineering and Technology, Nguyen Tat Thanh University, 300A Nguyen Tat Thanh Street, Ward 13, District 4, Ho Chi Minh City, 70000, Vietnam

    An-Le Van

  3. Department of Automatic Control, Ho Chi Minh City University of Technology and Education, No. 1 Vo Van Ngan Street, Linh Chieu Ward, Thu Duc City, Ho Chi Minh City, 70000, Vietnam

    Xuan-Ba Dang

  4. Hanoi University of Industry, No. 298, Cau Dien Street, Bac Tu Liem District, Ha Noi, 1000, Vietnam

    Phan Nguyen Huu

Authors
  1. Trung-Thanh Nguyen
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  2. An-Le Van
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  3. Xuan-Ba Dang
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  4. Phan Nguyen Huu
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Contributions

Conceptualization, T. T. Nguyen, A. L. Van, X. B. Dang; methodology, T. T. Nguyen, A. L. Van, X. B. Dang; software, T. T. Nguyen, A. L. Van, X. B. Dang; validation, T. T. Nguyen, A. L. Van, X. B. Dang; data curation, T. T. Nguyen, A. L. Van, X. B. Dang; writing—original draft preparation, T. T. Nguyen; writing—review and editing, T. T. Nguyen, A. L. Van, X. B. Dang; all authors have participated in the manuscript preparation and have read and agreed to the published version of the manuscript.

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Correspondence to An-Le Van.

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Nguyen, TT., Van, AL., Dang, XB. et al. Experiments and optimization of the hole EDM electrode’s parameters. Int J Adv Manuf Technol 127, 5373–5390 (2023). https://doi.org/10.1007/s00170-023-11855-7

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