Statistical analysis and optimization study on the machinability of beryllium-copper alloy in electro discharge machining

Beryllium-copper alloys have several industrial applications but are exposed to serious machinability challenges by conventional machining processes because of excessive tool wear and poor surface finish. This study explores the machinability of beryllium-copper alloy in an electro discharge machining process based on particularly dielectric medium parameters, oil and deionized water. Machinability characteristics were evaluated for material removal rate (MRR), electrode wear ratio (EWR) and the quality of the machined surfaces in terms of surface roughness (R-a). Experimental results were statistically analyzed and optimized using analysis of variance, Taguchi's orthogonal array and grey relation analysis. Response surface methodology has been used for modeling and prediction of the optimal experimental conditions. It was observed that the dielectric medium is a significant parameter, as is the working current for the machinability of beryllium-copper alloys. Electrode shape deformations, depending on electro discharge machining parameter variations, were also analyzed as an appendix section.