Experimental Investigation and Optimization of PM-EDM by Using Al Powder on Tungsten Carbide

Abstract

Electrical discharge machining (EDM) is an upgraded version of traditional EDM process; however, the material removal rate (MRR) is very less. To get better of this, an innovative machining process known as powder-mixed EDM (PM-EDM) is used, which helps to enhance not only surface finish but also MRR and productivity. In this study, the alliance between input parameters and output parameters with improved efficiency of the process in particular with the material removal rate (MRR) and tool wear rate (TWR) of PM-EDM is studied. The vital input parameters, like as gap voltage, pulse on time and peak current on material removal rate, tool removal rate, and surface finish of PM-EDM are studied in this experimentation. Tungsten carbide is used as workpiece material as it covers an ample range of applications in many industries, like as drilling and milling tools, industrial gear making, radiation shielding material applications, commercial construction applications, jewelry, surgical tools. Tungsten carbide has wide potential because of their excellent conductivity, resistant to heat, rust, scratches, pitting, incredible hardness, and resistance to wear and tear. For the machining of tungsten carbide components, electrical discharge machining (EDM) is used due to its difficult machinability and specific material properties. In this study, design of experiment (DOE) using full factorial method and optimization has been done by using gray relational analysis. Peak current and pulse on time are the most significant characteristics that determine the MRR and TWR, according to the analysis of variance.KeywordsTungsten carbidePM-EDMSurface finishMRRTWR