Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si3N4 Composite

Abstract

Machinability investigation of new material is one of the mandatory investigations to complete the purpose of creation of it. Electrical discharge machining (EDM) is one of the promising unconventional machining processes for highly accurate machining performance in difficult-to-cut material even machining complicated profiles. The powder-mixed EDM and nanopowder-mixed EDM are the improved versions of the EDM. The Al–Zn–Mg composite is reinforced with Si3N4 (9 wt. %) for meeting automotive and marine applications. The aluminium nanoparticles enhanced deionised water was used in NPMEDM. The nickel-coated brass and uncoated brass tube electrode were considered for the investigation. Pulse on time (µs), voltage (V), input current (A), and capacitance (nF) were independent variables and varied at 3 levels. The microhole machining performance with a coated and uncoated electrode was investigated. The L18 orthogonal array involved in the experimental design, material removal rate, and electrode wear rate were analysed. The SEM analysis was employed in the surface morphological study of electrodes before and after machining. The input parameters were optimised for the coated electrode for the responses of MRR and EWR.

An analysis on CNC machined surface roughness between AA7475 and AA7475/fly ash composite

“…Speed of the spindle (m/min) Different reinforcing ratios of fly ash to AL6061 were observed to affect the surface roughness of the fly ash reinforced AL6061 composite [16]. Using the Taguchi approach, the surface roughness of new Al/fly ash composites was determined in this study [17][18][19][20][21][22]. No contrary study analysis was found in the surface roughness findings.…”

Exploring the influence of powder particles in dielectric liquid of EDM: pulse train, discharge energy, material removal rate and surface topography

“…The nano powder mixed dielectric produced highest MRR of 47 mg min −1 and best surface roughness of 1.487 μm. Various other nano materials/powders like multi-walled carbon nanotubes [52], Al powder [53,54], graphene [55], silver [56], etc were mixed in the EDM dielectric and assessed for its feasibility to machine aerospace alloys. Their findings highlighted the significant impact of powder concentration, pulse on time, and pulse off time as the most influential factors, contributing towards varied MRR, surface roughness, and dimensional deviation (DD).…”