Parametric Analysis of Surface Modification of Die Steel using Powder Mixed

Dielectric and EDM

Mohammad Pervez Mughal

Department of Industrial Engineering, University of Management and Technology, Lahore

Abstract

An essential component of EDMed surface quality is surface integrity, which comprises surface
roughness, heat affected zone thickness, microhardness, and surface crater sizes. EDM produces
severely damaged surfaces with high roughness values, larger crater dimensions, and high deformed
layer thickness when it is used for rough machining. Distributed spark energy utilizing metallic powder
mixed with dielectric may produce machining results that are aesthetically pleasing while also improving
surface integrity. Powder reduces breakdown voltage, and the bridging effect, which increases series
discharge and produces shallow craters to enhance surface quality with a shallower heat impacted zone,
lowers breakdown voltage.

While maintaining electrical parameters constant, the current study examines the effects of powder
particle size, particulate percentage, and tool material on the machining of D2 steel. Using 66
experiments, the full factorial technique was employed with powdered copper, aluminum, and graphite
electrodes. As output parameters, we used material removal rate (MRR), surface roughness, crater size,
and surface hardness. The tool made of graphite with a 3 percent concentration of graphite power
produced the best MRR (4.077 mm3/min), while the tool made of aluminum with a 5 percent aluminum
powder of 1000 mesh size produced the lowest surface roughness (2.53 micron).