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Surface characterization and material migration during surface modification of die steels with silicon, graphite and tungsten powder in EDM process

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Abstract

The present study reports the results of an experimental work carried out to evaluate the improvement in machined surface properties of die steels machined using powder mixed electric discharge machining (PMEDM) process. Two surface responses, surface finish and microhardness were analyzed for changes when machined with Si, W and graphite powders mixed in dielectric fluid. The machined surfaces were subsequently analyzed using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) to study the element migration from powder, dielectric and the tool. The powder mixed with dielectric and its concentration, current and pulse on time were identified as the significant factors affecting surface finish. Brass electrode and tungsten powder resulted in good surface finish. Amongst the dielectrics used, kerosene provided a better cooling effect whereas EDM oil resulted in better surface finish. The microhardness of the machined surface was also affected by powder and its concentration, current, pulse on time and electrode material. W-Cu electrode and W powder resulted in a higher microhardness. The SEM and EDS analysis showed significant migration of material from the suspended powder, electrode and dielectric to the machined surface.

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Authors and Affiliations

  1. Mechanical Engineering Department, Thapar University, Patiala, 147-004, Punjab, India

    Anirban Bhattacharya, Ajay Batish & Naveen Kumar

Authors
  1. Anirban Bhattacharya
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  2. Ajay Batish
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  3. Naveen Kumar
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Correspondence to Ajay Batish.

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Recommended by Associate Editor Haedo Jeong

Anirban Bhattacharya graduated in Mechanical Engineering and earned his Masters degree in Manufacturing Technology. Presently he is working as Assistant Professor in Mechanical Engineering Department at Thapar University Patiala, India. He has almost nine years of teaching experience and has published many research papers in international and national journals.

Ajay Batish is PhD in Engineering and presently working as Professor and Head Mechanical Engineering Department at Thapar University Patiala, India. He has almost 9 years industry and 13 years of teaching and research experience. He has published many research papers in international and national journals of repute.

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Bhattacharya, A., Batish, A. & Kumar, N. Surface characterization and material migration during surface modification of die steels with silicon, graphite and tungsten powder in EDM process. J Mech Sci Technol 27, 133–140 (2013). https://doi.org/10.1007/s12206-012-0883-8

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  • DOI: https://doi.org/10.1007/s12206-012-0883-8

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