Abstract
The present study describes an experimental research on surface modification during electrical discharge machining (EDM) by depositing a hard layer over the work surface of C-40 grade plain carbon steel using specially prepared powder metallurgy compact tools. The investigated process parameters were composition, compaction pressure, sintering temperature, pulse on-time, peak–current setting, and duty factor. Measurements of deposited layer thickness, mass transfer rate, tool wear rate, surface roughness and microhardness were undertaken on the EDM-ed specimens. Different studies like X-ray diffraction, optical microscopy, scanning electron microscopy, and energy dispersive X-ray spectroscopy were carried out to ascertain the characteristics of the deposited layer on the work surface. These analyses confirmed the presence of the tool materials in the work surface layer. At first, an L-16 orthogonal array was applied as Taguchi DOE technique and the ANOVA was done to study the effects of pertinent process parameters. An optimum condition was achieved using overall evaluation criteria. Later on, a detailed study was carried out to get a smooth and regular deposition of material. The characterization of the deposited layer is presented. The deposited layer with a wide range of average layer thickness of 3–785 μm, enriched with tool materials (W and Cu) and with the formation of tungsten carbide, and having microhardness of 9.81–12.75 GPa at the hardest zone was successfully deposited over the work surface.
Similar content being viewed by others
References
Erden A (1983) Effect of materials on the mechanism of electric discharge machining (EDM). Trans ASME J Eng Mater Technol 105:132–138
Soni JS, Chakraverti G (1996) Experimental investigation on migration of material during EDM of die steel (T215 Cr12). J Mater Process Technol 56:439–451
Gangadhar A, Shunmugam MS, Philip PK (1991) Surface modification in electrodischarge processing with a powder compact tool electrode. Wear 143:45–55
Shunmugam MS, Philip PK, Gangadhar A (1994) Improvement of wear resistance by EDM with tungsten carbide P/M electrode. Wear 171:1–5
Samuel MP, Philip PK (1997) Power metallurgy tool electrodes for electrical discharge machining. Int J Mach Tools Manuf 37:1625–1633
Mohri N, Saito N, Tsunekawa Y, Kinoshita N (1993) Metal surface modification by electrical discharge machining with composite electrode. Anal CIRP 42:219–222
Mohri N, Fukusima Y, Fukuzawa Y, Tani T, Saito N (2003) Layer generation process on work-piece in electrical discharge machining. Anal CIRP 52:157–160
Fukuzawa Y, Kojima Y, Tani T, Sekiguti E, Mohri N (1995) Fabrication of surface modification layer on stainless steel by electrical discharge machining. Mater Manuf Processes 10:195–203
Moro T, Mohri N, Otsubo H, Goto A, Saito N (2004) Study on the surface modification system with electrical discharge machine in the practical usage. J Mater Process Technol 149:65–70
Simao J, Lee HG, Aspinwall DK, Dewes RC, Aspinwall EM (2003) Workpiece surface modification using electrical discharge machining. Int J Mach Tools Manuf 43:121–128
Simao J, Aspinwall D, El-Menshawy F, Meadows K (2002) Surface alloying using PM composite electrode materials when electrical discharge texturing hardened AISI D2. J Mater Process Technol 127:211–216
Aspinwall DK, Dewes RC, Lee HG, Simao J, McKeown P (2003) Electrical discharge surface alloying of Ti and Fe workpiece materials using refractory powder compact electrodes and Cu wire. Anal CIRP 52:151–156
Yan BH, Tsai HC, Huang FY (2005) The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. Int J Mach Tools Manuf 45:194–200
Wang ZL, Fang Y, Wu PN, Zhao WS, Cheng K (2002) Surface modification process by electrical discharge machining with a Ti powder green compact electrode. J Mater Process Technol 129:139–142
Tsai HC, Yan BH, Huang FY (2003) EDM performance of Cr/Cu-based composite electrodes. Int J Mach Tools Manuf 43:245–252
Zinelis S (2007) Surface and elemental alterations of dental alloys induced by electro discharge machining (EDM). Dent Mater 23:601–607
Patowari PK, Mishra UK, Saha P, Mishra PK (2006) Surface modification of C-40 steel using WC-Cu P/M green compact electrodes in EDM. Proc First International & 22nd All India Manufacturing Technology Design & Research Conference (22nd AIMTDR), India, pp 875–879
Roy RK (2001) Design of experiments using the Taguchi approach: 16 steps to product and process improvement. Wiley, New York
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Patowari, P.K., Saha, P. & Mishra, P.K. Taguchi analysis of surface modification technique using W-Cu powder metallurgy sintered tools in EDM and characterization of the deposited layer. Int J Adv Manuf Technol 54, 593–604 (2011). https://doi.org/10.1007/s00170-010-2966-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2966-y