Experiments and optimization of the hole EDM electrode’s parameters

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. © 2023, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.