https://orcid.org/0000-0002-3229-0650
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ABSTRACT
Aluminum powder-mixed EDM is operated on Nimonic C-263 with varied process parameters using eco-friendly deionized water as a dielectric. Performance evaluation includes material removal rate (MRR), tool wear rate (TWR), average surface roughness (Ra), EDM ratio (ER), and SEM analysis. MRR has been found to increase with higher peak current (Ipc), pulse-on-time (To), and pulse-off-time (Tf), achieving a peak of 2.183777 mm3/min at 12 A Ipc and 12 g/lit powder concentration (C). TWR is minimum (0.002455 mm3/min) at 12 g/lit C and 7 µs Tf. The least Ra (1.182 µm) is observed at 9 g/lit C and 7 µs Tf; however, it increases with higher duty cycle. ER rises with Ipc and Tf while it declines with To. SEM images reveal larger craters and debris globules at higher Ipc. Overall, optimized parameters enhance MRR while minimizing TWR and Ra, albeit with observed debris formation at higher Ipc.
Nomenclature
| List of symbols | = | |
| C | = | powder concentration, g.lit−1 |
| ER | = | EDM Ratio |
| D | = | duty cycle |
| Ipc | = | peak current, A |
| EDM | = | electric discharge machining |
| P | = | flushing pressure, kg/cm2 |
| PMEDM | = | powder mixed EDM |
| To | = | pulse-on-time, µs |
| MRR | = | material removal rate, mm3.min−1 |
| Tf | = | pulse-off-time, µs |
| SEM | = | scanning electron microscopy |
| Ra | = | surface roughness, µm |
| TWR | = | tool wear rate, mm3.min−1 |
Disclosure statement
No potential conflict of interest was reported by the author(s).