A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

Abstract

This comparative study investigates the effect of various magnetic field (MF) intensities on the precision machining of cylindrical workpiece of EN24 Steel alloy in the electrical discharge turning configuration. EN24 steel is a high-strength alloy commonly employed in aerospace, automotive, and general engineering applications. The objective of this research is to evaluate the impact of MF intensity on the material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness ( Ra). The rotational speed of the workpiece, peak current, and pulse-on time were kept constant machining parameters throughout the experiments. The experimental results reveal that increasing MF intensity enhances MRR, OC, and surface finish. However, it is observed that higher MF intensities lead to an elevate TWR which was a negative effect on machining performance. SEM analysis was conducted on the machined surface, revealing that higher magnetic intensity resulted in the formation of a reduced recast layer and remelted debris. The findings were further supported by energy-dispersive spectrum results, which indicated a lower presence of oxide and carbide formations on the machined surface when subjected to higher MF intensity.