Abstract
The present study reports the results of an experimental work carried out to evaluate the improvement in machined surface properties of die steels machined using powder mixed electric discharge machining (PMEDM) process. Two surface responses, surface finish and microhardness were analyzed for changes when machined with Si, W and graphite powders mixed in dielectric fluid. The machined surfaces were subsequently analyzed using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) to study the element migration from powder, dielectric and the tool. The powder mixed with dielectric and its concentration, current and pulse on time were identified as the significant factors affecting surface finish. Brass electrode and tungsten powder resulted in good surface finish. Amongst the dielectrics used, kerosene provided a better cooling effect whereas EDM oil resulted in better surface finish. The microhardness of the machined surface was also affected by powder and its concentration, current, pulse on time and electrode material. W-Cu electrode and W powder resulted in a higher microhardness. The SEM and EDS analysis showed significant migration of material from the suspended powder, electrode and dielectric to the machined surface.
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