Application of metal powder to improve metal removal rate in Electric Discharge Machining

Kavade, Mukund V.; Mohite, Suhas S.; Unaune, Deepak R.

doi:10.1016/j.matpr.2019.05.107

Cited by 11 publications

(3 citation statements)

References 6 publications

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“…112 Conductive and Semi-conductive powders yielded higher material removal whereas little to no effect on MRR was shown by non-conductive powders. 113 Kavade et al 114 and Kumar et al 115 through their experiments elucidated the effects of metal oxide and metal powder on MRR respectively. It was observed that as powder concentration increased, MRR increased up to a certain concentration, above which it remained almost constant.…”

Section: Meticulous and Lucid Study Of Powder Mixed Edmmentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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Section: Meticulous and Lucid Study Of Powder Mixed Edmmentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…MRR increases by increasing the concentration because the discharge increases which ultimately enhances the machining efficiency and reduces surface roughness [ 21 , 22 ]. Kavade et al [ 23 ] used Al powder with concentrations of 1–4 g/L in EDM. It was found that MRR significantly expanded by using Aluminum powder in a dielectric fluid for the roughing stage in EDM.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

et al. 2022

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Electric discharge machining with a powder mix dielectric is a promising technique to harden a work piece’s surface using electricity with a high energy density. The quality of the electrical discharge-machined surface is related to its surface integrity in which the surface’s roughness, residual stresses, micro hardness and surface micro cracks are some of the major factors. In this research, graphite powder was mixed in a dielectric with a particle size of 20 µm, 30 µm, and 40 µm, with the concentration of the graphite powder ranging from 2 g/L to 4 g/L. Moreover, the peak current and pulse time on were also coupled with an additive of graphite powder to investigate the effect on the surface quality, i.e., the recast layer thickness, micro hardness and crater depth as well as the material removal rate (MRR) and tool wear rate (TWR). A Box–Behnken design was employed to design the experiments and the experimental results revealed that the graphite powder size and concentration coupled with the electrical parameters (peak current and pulse time on) significantly influenced the recast layer thickness, micro hardness, crater size, MRR and TWR. The crater depth and micro hardness were maximized at a higher concentration and particle size, while the recast layer thickness was reduced with a higher gain size.

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“…Although all the previous mentioned research works have referred to the nanoparticles with high electrical and thermal conductivity to improving the machining performance, studies on the low-conductive nanopowders have also led to promising results. Among the nanoparticles with low thermal conductivity, only a few research-works have considered the aluminum oxide (Al 2 O 3 ) nanopowder particularly for the EDM process [15,[29][30][31]. It has been shown that this nanoparticle can improve the machining performance of the INCONEL 825 alloy in terms of MRR and surface roughness by 57% and 63%, respectively [29].…”

Section: Introductionmentioning

confidence: 99%

Influence of Zno nanoparticle addition and Spark Peak Current on EDM Process of AISI 1045, AISI 4140, and AISI D3: MRR, Surface Roughness, and Surface Texture

Pour¹,

Sm²,

El³

2021

Preprint

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In the recent studies, the effects of different metal oxide nanoparticles addition in different dielectrics of EDM process has been thoroughly investigated, showing that adding the nanoparticles improves the material removal rate and surface roughness. The results illustrate that the parameters such as density, particle size, particle concentration, and electrical and thermal conductivity of the nanoparticles can affect the process performance. Compared to the other metal oxides, ZnO has lower thermal and higher electrical resistance which makes it distinct from other nanoparticles used in EDM process in terms of physical properties. In this paper, the effects of the variation of peak current,and ZnO particle mass on MRR, surface roughness, and thermal conductivity of AISI1045، AISI4140, and AISID3 in EDM process are investigated. The results illustrate that 4 grams of the ZnO nanoparticle mass increase the MRR up to 10.71%, 50%, and 45.55%, for rough machining of AISI1045, AISI4140, and AISID3, respectively. In finish machining, they show that the surface roughness can be improved 16.66%, 29.41%, and 56.25%, respectively. It is observed that the amount of deposited particles on AISID3 is maximum followed by AISI 1045 and AISI4140. Therefore, in AISID3 both significant improvement of surface roughness and ZnO deposition can be achieved.

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Application of metal powder to improve metal removal rate in Electric Discharge Machining

Cited by 11 publications

References 6 publications

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Analysis of Particle Size and Concentration in Die Sinking Electric Discharge Machining

Influence of Zno nanoparticle addition and Spark Peak Current on EDM Process of AISI 1045, AISI 4140, and AISI D3: MRR, Surface Roughness, and Surface Texture

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