Investigating the Impact of EDM Parameters on Surface Roughness and Electrode Wear Rate in 7024 Aluminum Alloy

Electrical Discharge Machining (EDM) is a significant process in the industry for machining hard metals. It is a time-consuming and costly method that requires a high level of expertise to operate effectively. EDM is considered one of the unconventional operating processes due to its unique characteristics and the challenges associated with its implementation. One of the challenges facing researchers is determining the optimal parameters for achieving high surface quality while minimizing equipment consumption and associated costs. In addition to being classified as one of the operating processes, EDM processes are also classified as electro-thermal processes that affect surface quality. In this study, the influence of EDM parameters on surface roughness and electrode wear rate when machining aluminum alloy type 7024 was investigated. A total of 27 experiments were conducted to evaluate the impact of three parameters at three levels. The parameters under investigation include current, pulse on time, and pulse off time. Subsequent analysis of the results by variance analysis revealed that the most influential parameter for both surface roughness and electrode wear rate is electric current, with a rate of influence of 74%. The results were then subjected to further analysis using variable effect graphs to identify the optimal variables for achieving the best results. Finally, neural networks were employed to predict the results, with an accuracy of up to 99%.