International Journal of Research Available at https://edupediapublications.org/journals p-ISSN: 2348-6848 e-ISSN: 2348-795X Volume 06 Issue 13 December 2019 Available online: http://edupediapublications.org/journals/index.php/IJR/ Page | 277 Comparison Study between Experimental and ANFIS Results for Material Removal Rate in EDM Process Riyadh J. Fahad 1 , and Dr. Shukry H. Aghdeab 2 1,2 Department of Production Engineering and Metallurgy, University of Technology, Baghdad, Iraq Abstract: This work is a comparison study between experimental and ANFIS results focuses on studying the material removal rate (MRR) for five shapes under different conditions of pulse on time (T-on), current (I) and the shape of work piece (Sh w ). The major purpose of this study is to obtain the best MRR, by using a flat electrode of copper when machining five shapes (A,B,C,D,E). Experiment is carried out by using AISI 304 stainless steel specimens of thickness (2 mm). Different values of (T-on) (100,150 and 200) μs, and different currents of (10, 20 and 30) A were used. The experimental results reveal that the MRR enhances by an increase in the current values. Also the results show that the MRR improves with an increase in the (T-on). From the comparison between experimental and ANFIS results, the min. error is (0.0006) was obtained in shape (B), the max. error is (-0.0252) was obtained in shape (C). Keywords Material Removal Rate, Electrode Wear Rate, EDM, ANFIS. 1. Introduction Electrical Discharge Machining (EDM) is an important manufacturing process for machining alloys and hard metals irrespective of the hardness, such as, graphite, metallic alloys, or even some conductive ceramic materials. This process is widely used for producing molds, dies, and finishing parts for automotive, surgical components, and aerospace. The process is capable of getting surface finish and required accuracy by controlling the process parameters. EDM performance is generally evaluated on the basis of MRR, OC, SR and EWR. The important EDM parameters affecting to the performance measures of the process are (I), (T-on), (T-off), gap between the electrod and the w.p, and (τ) [1]. EDM has been replacing the almost all machining operations, and is capable of machining complex shapes or hard material components, that are precise and difficult-to- machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold, aerospace, medical and surgical, optical, automotive and nuclear industries [2,3]. 2. Principle of EDM Process Removal of metals by spark was first introduced by Joseph Priestily in 1878. EDM has no direct contact between the electrod and the w.p, and that eliminated the chance of mechanical stress, vibration and chatter problems [4]. EDM process is based on thermo-electric energy between the electrod and the w.p. A pulse discharge occurs in a small gap between the electrod and the w.p and removes the unwanted material from the material during melting and vaporizing processes [5]. electrod and w.p are separated by a spark gap (0.005 - 0.05mm) and both were immerged in a suitable dielectric (non- conductor of electricity), is forced through this gap at a certain pressure. When a proper voltage is applied the dielectric breaks down and electrons are emitted from cathod and the gap became ionized, as in Figure (1) [6]. Then many electrons collection in the gap, consequently the resistance drops causing electric spark to jump between the electrod and w.p. Sparking occurs in a frequency rang from (2.000 - 500.000 sparks per sec.). Each electric discharge causes a focused stream of electrons to move with a very high velocity, and that lead to raise the temp. more than (10.000 C°). Each spark produces a tiny crater by erosion of material. The spark removes