Die-sinking electrical discharge machining with a constant spark gap uses a LASER-machined electrode with 38 holes of 0.16 mm diameter to machine a Molybdenum disilicide and Silicon Carbide (MoSi2-SiC) ceramic composite for high-temperature and high-performance applications like aerospace components, gas turbine parts, heating elements, and nuclear systems. Qualitative results are shown through EDM using multi-hole copper electrodes and pure EDM fluid to create holes in MoSi2-SiC.Significant performance outcomes, including trends in MRR, EWR and surface roughness (Ra), have been explicitly quantified. A design of experiments and analysis of variance (ANOVA) were employed to examine the link between experimental variables and outcomes.Pulse current is the most significant metric for Ra, with pulse on-time ranking closely behind.This study implemented Taguchi-Data Envelopment Analysis-based Ranking (DEAR) for identifying the optimal multi-response optimization parameter.Experimental research reveals optimal EDM settings for MoSi2-SiC ceramic composite, including laser-drilled multi-hole copper electrode, 3 A peak current, 7 μs pulse-on time, 4 μs pulse-off time, and 14 Kg/cm2 dielectric pressure. Microstructural analysis will be done for each experiment session to find any unusual features in the machined composites. Machining time, flushing efficiency, and productivity are enhanced by laser-drilled multi-hole electrodes. The Taguchi-DEAR optimization method is used to balance performance outcomes, making it effective for practical EDM process improvements.
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