Abstract
Electric discharge machining (EDM) process consisting conductive powders has been quite popular for hard materials machining with acceptable dimensional and geometrical accuracy. However, issues like unacceptable surface quality, high tool wear rate (TWR) and low material removal rate (MRR) limits the applications of this non-conventional technique. In this article, effort has been made to identify the parametric conditions that resulted in maximum MRR and minimum TWR during powder (nickel) mixed EDM operation of various die steels having similar applications (EN8, EN19 and EN24) by copper tool. Since the MRR in EDM process has been affected significantly by variation in peak current, off and on-time of pulse, so these three parameters along with concentration of conductive powder have been selected as input variables in the research work. The experiments (total 36) were executed and analyzed using D-optimal design criterion of response surface methodology (RSM) technique.
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