Optimization and Modelling of Crater Formation in Electrical Discharge Machining of AA5052 Alloy

Electrical discharge machining (EDM) is the primary technique employed to fabricate precious components for aircraft applications from AA5052 alloy through the die-sinking process. This research optimizes EDM parameters for AA5052 alloy, concentrating on crater shape, material removal rate and surface quality. A structured L9 orthogonal matrix design is used to test gap voltage, discharge duration and discharge current. The examination of the results takes into account the input of energy while machining and material surface transformation. In the finite element method, to model the phase change with heat volumetric strain variation, a defined by users function is implemented. SEM analysis reveals notable crater morphologies and recast layer formations, consistent with theoretical predictions. The developed FEM model predicted crater geometry with an average error of 5.65% (R 2 = 86.46%), demonstrating good agreement with experimental measurements. The optimal progression restrictions are obtained through a Hybrid Taguchi-Grey Relationship Analysis. Optimized machining conditions (6A peak current (P c ), 200 μs discharge time (D t ), 90 V gap voltage (G v )) result in better surface quality and less electrode wear. The confirmation experiment showed only a 3.2% deviation between the predicted and experimental Grey Relational Grade. The suggested framework forecasts crater size with small absolute error, giving robust guidance for precision machining applications.