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An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance

  • Research Article-Mechanical Engineering
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Abstract

In this work, a highly carbonated liquid has been utilized as a dielectric medium in the EDM process. The effect of the dielectric medium has been investigated and then, finally, compared with EDM oil. The outcomes have demonstrated that discharge energy density has escalated to fierce-extent, thus, removing a voluminous amount of material from the workpiece. The results also emphasize that the dielectric medium has a viscosity (8.6 CS) higher than EDM oil (2.16 CS) is helpful for higher MRR. The debris particle has remained suspended in the dielectric medium due to its highly viscous properties leading to high MRR without any flushing technique. The process parameters, pulse-on-time, and peak current have dramatically influenced the EDM process. Further, the surface morphology has also been investigated. Results have also revealed that at a low peak current value, the MRR has increased by 155.55%, whereas, at a low value of pulse-on-time, MRR has decreased by 28.25%. At a high peak current value, MRR has increased by 217.55%, whereas, at a high value of pulse-on-time, MRR has increased by 324.05%. The highly carbonated liquid dielectric has considered the most suitable dielectric medium for high discharge energy. Micro-crack density and size have increased with MRR because of highly concentrated discharge energy. The recast layer thickness has increased with the dielectric medium's viscosity because of improper molten metal flushing, and the molten metal re-solidifies on the same surface.

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Abbreviations

HSTR:

High strength and temperature resistant

Ra:

Surface roughness

FE-SEM:

Field emission scanning electron microscopy

TWR:

Tool wear rate

EDM:

Electric discharge machining

HCL:

Highly carbonated liquid

EPMA:

Electron probe microscopy element

MRR:

Material removal rate

HAZ:

Heat-affected zone

T on :

Pulse on time

Ip:

Peak current

AFM:

Atomic force microscopy

ANOVA:

Analysis of variance

WEDM:

Wire EDM

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Authors and Affiliations

  1. Indian Institute of Technology (Indian School of Mines), Dhanbad, 826004, India

    Kamlesh Paswan & Somnath Chattopadhyaya

  2. School of Civil and Mechanical Engineering, Curtin, University, Perth, WA, Australia

    Alokesh Pramanik

  3. Department of Mechanical Engineering, University Centre for Research and Development (UCRD), Chandigarh University, Mohali, 140413, India

    Shubham Sharma & Sunpreet Singh

  4. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266520, China

    Shubham Sharma

  5. Department of Mechanical Engineering, Indian Instititue of Technology Bombay, Mumbai, India

    Gurminder Singh

  6. Faculty of Engineering and Technology, Department of Mechatronics Engineering, University of Chakwal, Chakwal, 48800, Pakistan

    Aqib Mashood Khan

  7. Department of Mechanical Engineering, National University of Singapore, Singapore, 119077, Singapore

    Sunpreet Singh

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  1. Kamlesh Paswan
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  2. Alokesh Pramanik
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  4. Shubham Sharma
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  5. Gurminder Singh
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Contributions

KP: conceptualisation, methodology, investigation, software, writing—original draft preparation. AP: conceptualisation, methodology, investigation, software, writing—original draft preparation. SC: conceptualisation, supervision, validation, writing—reviewing and editing. SS: conceptualisation, supervision, validation, writing—reviewing and editing. GS: supervision, visualization, writing—reviewing and editing. AMK: supervision, visualization, writing—reviewing and editing. SS: supervision, visualization, writing—reviewing and editing.

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Correspondence to Kamlesh Paswan or Shubham Sharma.

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Paswan, K., Pramanik, A., Chattopadhyaya, S. et al. An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance. Arab J Sci Eng 48, 11941–11957 (2023). https://doi.org/10.1007/s13369-023-07626-x

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