Optimal parameter settings for rough and finish machining of die steels in powder-mixed EDM

  • Anirban Bhattacharya
  • Ajay Batish
  • Gurmail Singh
  • V. K. Singla


The present study was undertaken to identify the appropriate parameter settings for rough and finish machined surface for EN31, H11, and high carbon high chromium (HCHCr) die steel materials in a powder-mixed electric discharge machining process. The effect of seven different process variables along with some of their interactions was evaluated using a dummy-treated experimental design and analysis of variance. Material removal rate (MRR), tool wear rate, and surface finish were measured after each trial and analyzed. The parameter settings for rough and finished machining operations were obtained. EN31 exhibited maximum MRR as compared to the other two materials at similar process settings. Copper (Cu) electrode with aluminum suspended in the dielectric maximized the MRR. Suspending powder in the dielectric resulted in surface modification. Graphite powder showed a lower MRR but improved the surface finish. HCHCr require higher current and pulse on settings for initiating a machining cut and works best in combination with tungsten–Cu electrode and graphite powder for improved finish. The MRR for H11 is lower than EN31 but significantly higher than HCHCr under same process conditions.


Powder-mixed dielectric Electric discharge machining Material removal Tool wear Surface finish Rough machining Finish machining 


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Copyright information

© Springer-Verlag London Limited 2011

Authors and Affiliations

  • Anirban Bhattacharya
    • 1
  • Ajay Batish
    • 1
  • Gurmail Singh
    • 1
  • V. K. Singla
    • 1
  1. 1.Mechanical Engineering DepartmentThapar UniversityPatialaIndia

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