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The exploration of Electrical Discharge Machining (EDM) with coated electrodes represents a relatively novel research avenue, thereby yielding limited published research outcomes. The choice of coating material plays a pivotal role in the EDM machining process, and alterations in coating materials can directly influence the adjustment of technological parameters in EDM. Consequently, research dedicated to optimizing these technological parameters for EDM employing coated electrodes is of paramount importance, and it promises to advance the practical implementation of this cutting-edge technique. In this study, we systematically investigate the technological parameters for EDM employing a copper-coated aluminum electrode in the context of Ti-6Al-4V machining. Our research outcomes are framed within a multi-objective optimization paradigm, with a focus on Material Removal Rate (MRR) and Surface Roughness (SR) as vital quality indicators. To address the intricate multi-objective optimization challenge, we have harnessed the combined power of the Taguchi methodology and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The amalgamation of these techniques enables us to navigate the complexities of EDM parameter optimization effectively. Our findings reveal that the most favorable process parameters entail a configuration of U=40V, I=40 A, Ton=1000μs, resulting in an MRR of 0.028mg/min and an SR of 7.56μm. These optimized parameters exemplify a substantial enhancement in machining efficiency and surface quality when utilizing coated electrodes. Moreover, our study scrutinizes the quality of the machined surface under optimal conditions with coated electrodes. We employ the TOPSIS method as a proficient solution for this endeavor, offering a straightforward approach to this intricate calculation process. [ABSTRACT FROM AUTHOR]

In this study, the effects of low-frequency vibrations on machining SKD61 steel workpiece in electrical discharge machining (EDM) with titanium powder-mixed dielectric fluid were investigated. The results showed that the vibrations incorporated into the workpiece in powder-mixed EDM (PMEDM) led to significant improvement in machining efficiency. The material removal rate had the maximum increase of 141.7% with 70.2% of lower electrode wear rate and 69.9% of lower surface roughness. Hence, it is proved that the effectiveness of vibration in PMEDM can be improved. [ABSTRACT FROM AUTHOR]