An experimental investigation on copper square electrode wear in electric discharge machining of Hastelloy B2.

Hastelloy B2 is a high-performance nickel-molybdenum alloy and has been used in micro reactor, pump, pipe, and corrosion-resistant equipment. Square holes are required in the above application components. Although square holes are easily produced by spending more electrodes wear in Electrical Discharge Machining (EDM). Moreover, the square hole with small electrode wear achieved is a challenging task in thermal machining. Hence, in this work, the effects of EDM process parameters on electrode taper angle, electrode radius, electrode wear length and cutting time of Hastelloy B2 are studied. Taguchi based VišekriterijumskoKompromisnoRangiranje (VIKOR) method is used to find the optimum process parameters and compared with Taguchi based Grey Relational Analysis (GRA) method for validation. The results showed that current and pulse duration greatly affects the electrode wear out surface and edges. The square electrodes with sharp edges and surfaces are fully transformed into hemispherical shapes at electrode ends due to an unstable spark with diffusion of heat. Also, the VIKOR method provides an alternative multi-criteria optimization method that enhances the process performance over the grey relational analysis due to comparability, uniqueness, assessment and prediction.