Jindal, S.Singh, Deepa2020-09-172020-09-172019Singh D. and Jindal S.https://krishikosh.egranth.ac.in/handle/1/5810151402Optimization of Process Parameters in Electric Discharge Machining (EDM) of Heat Treated Carbon Tool Steel (SK2MCr4)Manufacturing with machining contributes to a larger extent in most of the industry as even the formed parts needs finishing by removal of material. The conventional machining processing involving common machine tools is making use of modern technology high production through better tooling and computer numerical control machining. The conventional material can be process with normal tools and machined with ease and little stress on the system. But special alloys, with high hardness and toughness are difficult to be worked on by these machines. Especially heat treated components acquire such a high degree of surface hardness that these are impossible to be cut with the best of tool materials available as on date. To take care of these challenges, modern machining method has be evolved using non-conventional approaches for metal removal, such as Electric discharge machining (EDM). In this work, experiments are carried out to investigate the effect of process parameters on material removal rate of machined workpiece specimens and it is observed that the rate of material removal rate is calculated with high degree of accuracy after the machining process. The experiments are performed on ZNC-250 die-sink electric discharge machine for EDM drilling of SK2MCr4 carbon tool steel workpiece using copper rod as electrode. Experiments are designed using fractional and full factorial design of experiment (DOE) and experimental runs were conducted for various combinations of process parameters such as current (I), pulse on time (Ton), servo voltage (V) and keeping pulse off time (Toff) as constant. Analysis of variance (ANOVA), and regression techniques were employed to study the performance characteristics at different conditions and levels according to DOE. It is found that the MRR is mainly influenced by current where as other two parameters i.e. pulse on time and servo voltage have lesser effect on material removal rate. The maximum MRR is 16.24 mm³/min. The percentage contribution of the current, pulse on time and servo voltage are found to be 64.29%, 25.78% and 4.04% in fractional DOE approach while in full factorial DOE 95 approach, the percentage contributions are 62.05%, 26.39% and 1.09% respectively. The optimum combination of (I), (Ton) and (V) for maximizing MRR is found as 12A, 60 �s and 3V respectively. The results obtained by this research will be useful for various industries and researchers working in this field.EnglishThesis