Enhancing the machinability of SKD61 die steel in power-mixed EDM process with TGRA-based multi criteria decision making

In the current context, an attempt is being made to improve the electrical discharge machining (EDM) process by using powder particles in a suitable combination. To improve the quality of such procedures, the process parameters should be optimized. The present study proposes to utilize Taguchi–Grey relational analysis to discover the optimal combination of process parameters for SKD61 die steel specimens using titanium powder-mixed EDM (PMEDM). Among the machining parameters chosen, the optimal combination of current (3 A), pulse on-time (37 μs), pulse off-time (37 μs), and powder concentration (4 g/L) was determined experimentally. Due to its relevance in spark energy production, peak current is a more significant factor in PMEDM processes. A superior surface topography was obtained with increased microhardness and fewer microfractures over machined specimens with optimal process parameter in PMEDM. The titanium particles can effectively enhance the surface performance measures during PMEDM-based machining owing to tiny craters and pores with better lubrication.