Multi-criteria decision making-based optimization of thermal modeling of electric discharge machining

A thermal model was developed based on finite element modeling analysis using the Transient Thermal module of Ansys. The objective of this study was to develop a thermal model for electrical discharge machining to address the discrepancies observed in the model proposed by Ming et al., which failed to accurately estimate Material Removal Rate (MRR) values for discharge powers exceeding 100 mJ. The MRR ratios derived from the model under consideration were observed to be within the range of 3.568–0.639. In comparison, the MRR ratios obtained from the models proposed by Ming et al. and Joshi et al. were found to be within the range of 3.566–1.186 and 40.433–0.652, respectively. Thus, the thermal model presented in this study demonstrates exceptional precision in predicting the MRR and surface roughness (SR) when compared to previously established models. The optimization of the readings was carried out through the application of Technique for Order of Preference by Similarity to Ideal Solution. The results indicated that an optimized MRR and SR were achieved at a pulse current (I) of 58 amps, pulse on time (Ton) of 420 μs, pulse off time (Toff) of 7.5 μs, and discharge power of 609 mJ.