Modeling the machining parameters of AISI D2 tool steel material with multi wall carbon nano tube in electrical discharge machining process using response surface methodology

Abstract

This work investigates the machining characteristics of American Iron and Steel Institute (AISI) D2 tool steel with copper as a tool electrode during electrical discharge machining (EDM) process. The multi wall carbon nano tube (MWCNT) is mixed with dielectric fluids in EDM process to analyze the surface characteristics of surface roughness. Regression model were developed to predict the surface roughness (SR) in EDM process. In the development of predictive models, machining parameters of pulse current, pulse duration and pulse voltage were considered as model variables. The collection of experimental data adopted Box-Behnken central composite design (CCD). Analysis of variance (ANOVA) and F-test were used to check the validity of regression model and to determine the significant parameter affecting the surface roughness. Later, the AISI D2 tool steel was analyzed and the parameters are optimized using MINITAB software, and regression equation are compared with and without MWCNT used in EDM process. The average 34% of surface finish was improved by using carbon nano tube (CNT) mixed as dielectric fluid. The maximum test errors for regression model using copper electrode are 8.18% for without CNTs and 5.44% for with CNTs. The R 2 value of developed empirical model for SR with MWCNTs is 69.45% compared without CNT is 55.4%. The high R 2 value indicates that the better the model fits the data.

Effect of Carbon Nano Tube Addition with Dielectric Fluid in Die Sink EDM

“…High resistance to corrosion abrasion surface is produced by PMEDM process [3][4][5]. So many research works was [8,[11][12][13][18][19][20][21]23,25,26,36,37]. In spite of the improved results, practical application of NPMEDM in industry is very low rate.…”

State of the art in powder-mixed electric discharge machining: A review

“…Wong et al 22 utilized crushed glass as an additive to machine AISI-01, SKH 54 tool steels and found no significant effect of it on both MRR and surface quality due to its very poor electrical and thermal conductivities. Sari et al 20 and Prabhu and colleagues 48–51,53–56 concluded that carbon nanotubes (CNTs) mixed in the dielectric resulted in huge improvement of MRR compared to other powder materials. This phenomenon was attributed to the low density and high thermal conductivity of CNT.…”

Relevance Vector Machine Based Analyses of MRR and SR of Electrodischarge Machining Designed by Response Surface Methodology

“…The most influencing factor in this study was found to be discharging current [6]. Another notable study by Prabhu and Vinayagam [7] was on the modelling and characterization of EDM process parameters of AISI D2 toll steel material with multiwall carbon nanotubes and developed the prediction of SR as response parameter and pulse current, pulse duration, and pulse voltage as model variables with copper electrode using Box-Behnken in RSM. Li and Lee [8] studied the different optimal machining parameters (voltage, discharge current, pulse on time, and flushing pressure) setting and electrode polarity (copper tungsten electrode) on response parameter MRR and SR by implementing RSM.…”