The current research uses Taguchi grey relational analysis to optimize the process parameters in micro electro discharge machining of silicon steel using nickel-coated brass (NCB) tool and waste cashew shell oil-activated water-based dielectric. The key goal of this study was to determine the most influencing process parameter, which had the greatest impact on material removal rate (MRR) and tool wear rate (TWR) while drilling silicon steel. Another goal was to optimize the micro EDM process parameters to achieve high MRR with reduced tool wear rate in coated tools. Using the electroless plating process, a 0.47 mm brass tool was coated with 0.5, 1.0, and 2 µm nickel; similarly, the dielectric medium was activated using 5, 10, and 15 wt.% of cardanol oil. The method parameters were optimized using an orthogonal array and a grey method. In the micro EDM drilling method, grey relational analysis was used to evaluate the most affecting parameters, such as gap voltage, coating thickness, and cardanol oil percentage. Due to the increase in electron transfer, the cardanol oil percentage was found to be the most influencing process parameter among others. At second, the gap voltage dominates the machining process. It is noted that the optimized process parameter was A₃B₁C₃, which had an MRR of 9.69 mm³/min and a tool wear rate (TWR) of 1.09 mm³/min, as well as a grey relational grade of 0.749. Thus, the grey relational grade value of confirmation experiment is increased by 2.04% over the predicted mean value of 0.734.

目前的研究采用田口灰色关联分析，优化了使用镀镍黄铜（NCB）工具和废腰果壳油活化水基电介质对硅钢进行微放电加工的工艺参数。本研究的主要目标是确定对硅钢钻孔时材料去除率 (MRR) 和刀具磨损率 (TWR) 影响最大的工艺参数。另一个目标是优化微 EDM 工艺参数，以实现高 MRR 并降低涂层刀具的刀具磨损率。使用化学镀工艺，在 0.47 mm 黄铜工具上镀上 0.5、1.0 和 2 µm 镍；同样，使用 5、10 和 15 wt.% 的腰果酚油激活电介质。使用正交阵列和灰色方法优化方法参数。在微电火花钻孔方法中，灰色关联分析用于评估影响最大的参数，如间隙电压、涂层厚度和腰果酚油百分比。由于电子转移的增加，腰果酚油百分比被发现是影响最大的工艺参数。其次，间隙电压在加工过程中占主导地位。值得注意的是，优化的工艺参数为 A₃ B ₁ C ₃，其 MRR 为 9.69 mm ³ /min，刀具磨损率 (TWR) 为 1.09 mm ³ /min，灰色相关等级为 0.749。因此，确认实验的灰色关联等级值比预测平均值 0.734 增加了 2.04%。