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How Suspended Particles Affect Surface Morphology in Powder Mixed Electrical Discharge Machining (PMEDM)

Abstract

The effect of SiC powder mixing into the dielectric liquid on surface topology and structure of interstitial free (IF) steel has been studied. Four process parameters, namely pulse duration, pulse current, concentration of powder, and type of dielectric liquid material, have been selected as varying parameters. Surface modifications due to suspended SiC particles were identified by using optical, scanning electron microscopy, and X-ray diffraction analysis. It was observed that suspended particles around discharge column accelerated and gained sufficient velocity to penetrate to the molten pool before solidification by means of electrophoresis and negative pressure induced after cessation of a discharge, which leads a surface embedded with added fine particles under that prevent formation of penetrating cracks during machining. However, surface cracks that formed due to high transformational stresses developed during solidification were found to be unaffected by means of mechanical action of the particles.

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Acknowledgments

This work is supported by Bülent Ecevit University Research Fund Grant No. 2007.2.45.03.04.

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Correspondence to Bülent Ekmekci.

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Manuscript submitted March 6, 2012.

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Ekmekci, B., Ersöz, Y. How Suspended Particles Affect Surface Morphology in Powder Mixed Electrical Discharge Machining (PMEDM). Metall Mater Trans B 43, 1138–1148 (2012). https://doi.org/10.1007/s11663-012-9700-0

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  • DOI: https://doi.org/10.1007/s11663-012-9700-0

Keywords

  • Material Removal Rate
  • Electric Discharge Machine
  • Molten Pool
  • White Layer
  • Electric Discharge Machine Process