Experimental Investigation of the Effect of Input Control Variables in Near Dry Electric Discharge Drilling Process

Abstract

Abstract Electric Discharge Machining (EDM), in its dry state (also known as Dry-EDM), appears to be as one of the best non traditional machining processes in terms of its suitability with the environment but carrying a demerit of slower material removing rate along, though in case of Near Dry Electric Discharge Machining (N-D-EDM) more amount of discharge energy claims to overcome this demerit along with a significant reduction in the roughness of the surface and less deposition of debris. A N-D-EDM consists of the application of a mixture of liquid & gas which helps in acclimating the characteristics of liquid and di-electric as per the requirements of the research. The present research elucidates the investigation of the optimal levels of input control variables of Near Dry Electric Discharge Drilling (N-D-EDD) process in machining of blind holes of Al6063/10% SiC Metal Matrix Composites (MMCs). The input control variables of choice were discharge-current, pulse-on-time, duty-factor and tool-speed, while material removal rate (MRR) was chosen as the performance characteristic during the N-D-EDD. Design of Experiments and Response Surface Method (RSM) were implemented and tool-electrode with rotary motion was used to drill blind holes. The results of the experimental trial runs depicted that the selected input control variables of N-D-EDD had significant effects on MRR.