Powder mixed electrical discharge machining: One step method to create functional surfaces

Abstract

The present work proposes a novel single stage technique to establish functional surfaces on machined component through powder mixed EDM process. A comparative analysis on surfaces generated by MoS2 powders of two distinct sizes Ф 40 µm (µP) and 90 nm (nP) mixed into dielectric of EDM is explored. Current (Ip) is chosen as input parameter and its consequence on Rq, Rsk, Rku, recast layer thickness (RCLT) and EDS analysis of AISI 304 machined surface is assessed. The Rq grows in proportion to rise in Ip magnitudes for both µP and nP mixed dielectric. At smaller magnitudes of Ip, a unique combination of negatively skewed and positive kurtosis surfaces are generated in both µP and nP mixed dielectric. The RCLT grows with increasing Ip magnitudes and the deposition of MoS2 on machined surface is perceived through EDS profiles.