Abstract

Conventional machining process has the limitation when desired surface finish and dimensional accuracy in geometry is required in difficult to machine aerospace materials especially for the cases of drilling holes. Non conventional advance machining processes (AMPs) are extensively used in the industry to machine for the complex geometrical dimension along with desired surface finish in hard materials. Electrical Discharge machining with modification for holding and rotating the electrode has been used in the present experiment for making holes in the Nimonic alloy. This paper investigate the influence of gap current, pulse on time, duty factor, tool electrode rpm and especially the polarity of the machine on Material Removal Rate (MRR) and surface roughness (Ra) for machining of Nimonic alloy. It is observed that with suitable control of input parameters of Electrical Discharge drilling (EDD), MRR and Ra both found to be improving together from 60 to 90 mg and 4.8 to 2.9 µm respectively which confirm the viability of using tool electrode rotation in EDM machining.

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