Abstract
In this research, the modeling of the black layer formed on tool and its influence on tool wear is assessed while machining AISI 4340 in die-sinking EDM. Response surface methodology with rotatable CCD is used with peak current, pulse on duration, voltage and pulse duty factor as process parameters. Tool wear is estimated using the selected set of parameters. The results of ANOVA elucidates that the present model is significant. Pulse duty factor and peak current are found to have crucial significance on tool wear. The SEM images and EDX revealed that the black layer formed on the tool contains silicon, iron and oxygen along with carbon. At higher levels of pulse duty factor, the appearance of black layer is more distinct.
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