Abstract
In the present study, the powder mixed EDM (PMEDM) process was simulated using FE approach to obtain simulated temperature profiles for estimating the crater dimensions and volume removed during formation of each crater. The craters formed in PMEDM process had higher diameter and shallow depth resulting in improved MRR and better surface finish. The addition of powder increased the amount of heat available at the workpiece between 20-25% as compared to conventional EDM process. The results were subsequently validated experimentally to compare the actual measurements with the simulation output. Predictor equations for crater radius and depth incorporating the significant factors were developed and also validated with the experimental results.
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