Optimization Of Machining Parameters Of Powder Mixed EDM Process

Mechanical Engineering

Scientifically emerging industries like automotive, defense, aerospace, electronics, nuclear power, metallic moulds and dies requires materials of high strength, high temperature resistant alloys like carbides, super alloys, haste-alloys etc. Manufacturers strive hard to produce these components at lower cost and of esteem quality as they have a direct impact over the profit earned by the firm. Hence, the productivity can be improved by increasing the material removal rate (or) by reducing the machining time of the product. Addition of a fine conductive powder to the dielectric fluid decreases its insulating strength and consequently increases the inter-electrode space causing an easy removal of the debris. The process variables of PMEDM play a considerable role in material removal mechanism. Performance of the PMEDM process depends upon characteristics like powder type, concentration, particle size, and electrode area and work piece constituents. As a result, the process becomes more stable, thereby, improving the material removal rate (MRR) and surface finish. Moreover, the surface develops high resistance to corrosion and abrasion. In this study, we have chosen the OHNS (Oil Hardened Non Shrinking) die steel as work piece material. A copper electrode and brass electrode with a diameter of 10 mm was used to cut the work piece in EDM. Commercial kerosene has been chosen as dielectric fluid. The consequence of the Machining parameters such as Pulse ON time, Pulse OFF time and current over the Machining time and Surface Roughness has been analyzed. The interaction study is made by Response Surface methodology.

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