Optimization of EDM parameters for enhanced machining of X37CrMoV5-1 tool steel using taguchi method and regression analysis

Electrical Discharge Machining (EDM) is a vital non-traditional process for shaping hard-to-machine alloys used in precision tooling applications. This study experimentally investigates the machining performance of X37CrMoV5-1 tool steel under varying EDM parameters: peak current (Ip), pulse-on time (Ton), duty cycle (DC), and gap voltage (Vg). Experiments were conducted using the Taguchi L9 orthogonal array, and regression models were developed to predict Material Removal Rate (MRR) and Tool Wear Rate (TWR). The results revealed that peak current had the most dominant influence on both responses, contributing approximately 64.3% to MRR and 57.8% to TWR variation. The optimal parameters for maximizing MRR were found to be I_P = 9 A, T_ON = 155 µs, DC = 28%, and Vg = 50 V., while the optimal conditions for minimizing TWR were I_P = 3 A, T_ON = 210 µs, DC = 19%, and Vg = 50 V. The machining conditions achieved an MRR of 5.8538 mm³/min and a TWR of 0.0535 mm³/min, representing a 27.5% improvement in MRR and 21.3% reduction in TWR compared to previously reported studies on similar tool steels. The regression models showed high accuracy with R² values exceeding 0.987, confirming their suitability for performance prediction. Overall, the study demonstrates that controlled adjustment of Ip and Ton significantly enhances EDM efficiency for X37CrMoV5-1 tool steel.