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P. Venugopal1

, K.G. Saravanan2

, R. Thanigaivelan3

1Muthayammal College of Engineering, Department of Mechanical Engineering, Rasipuram, India
2Sona College of Technology, Department of Mechanical Engineering, Salem, India
3AKT Memorial College of Engineering and Technology, Department of Mechanical Engineering, Kallakurichi, India

Received: 11 December 2022
Revised: 11 February 2023
Accepted: 20 February 2023
Published: 31 March 2023


Electro discharge machining (EDM) process is applied to machine hard and difficult to cut materials. In this research hard material namely, grey cast iron is used as a workpiece and copper electrode 2 mm in diameter is used for making holes through EDM process. The effect of input parameters such as pulse-on time (Ton), pulse off time (Toff), gap voltage (Vg) and current (I) on material removal rate (MRR) and tool wear rate (TWR) were studied. Based on Response Surface Methodology (RSM) analysis the gap voltage and pulse on time has significant impact on MRR and TWR respectively. The mathematical model is developed for MRR and TWR using RSM. Analysis of variance (ANOVA) shows that voltage has notable impact on MRR. Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) is used to estimate the best combination for higher MRR and lower TWR. Based on the analysis the estimated combination is pulse-on time of 45 μs, pulse-off time of 3 μs, gap voltage of 25 V and current of 10 A.


Electro discharge machining, gap voltage, material removal rate, tool wear rate


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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)

Volume 9
Number 1
March 2024

Last Edition

Volume 9
Number 1
March 2024

How to Cite

P. Venugopal, K.G. Saravanan, R. Thanigaivelan, Performance Analysis of EDM on Grey Cast Iron Using RSM and TOPSIS Method. Applied Engineering Letters, 8(1), 2023: 10-16.

More Citation Formats

Venugopal, P., Saravanan, K. G., & Thanigaivelan, R. (2023). Performance Analysis of EDM on Grey Cast Iron Using RSM and TOPSIS Method. Applied Engineering Letters8(1), 10-16.

Venugopal, P., et al. “Performance Analysis of EDM on Grey Cast Iron Using RSM and TOPSIS Method.” Applied Engineering Letters, vol. 8, no. 1, 2023, pp. 10-16,

Venugopal, P., K.G. Saravanan, and R. Thanigaivelan. 2023. “Performance Analysis of EDM on Grey Cast Iron Using RSM and TOPSIS Method.” Applied Engineering Letters 8 (1): 10-16.

Venugopal, P., Saravanan, K.G. and Thanigaivelan, R. (2023). Performance Analysis of EDM on Grey Cast Iron Using RSM and TOPSIS Method. Applied Engineering Letters, 8(1), pp.10-16. doi: 10.18485/aeletters.2023.8.1.2.