Study on Optimization and Machining Characteristics of Electric Discharge Machining Using Powder Suspension Dielectric Fluids

Abstract

EDM (Electric Discharge Machining) is a thermo-electric non-traditional machining process in which material removal takes place through the process of controlled spark generation between a pair of electrodes which are submerged in a dielectric medium. The present study has been done to study the effect of different input parameters namely current, work piece material, dielectric medium, powder, pulse on time, tool angles, powder concentration on the MRR, TWR and WR. The effect of various input parameters on output responses is analyzed using statistical techniques such as ANOVA. Optimization and verification of the process parameters and the modeling of the results is done by applying Regression Analysis. Surface roughness and geometric accuracy has also been studied. XRD and microstructure analysis has been performed to understand the form and deposition on the surface of the workpiece material. Main effect plots for the significant factors and S/N ratio have been used to determine the optimal design for output response.