Improvement in Machined Surface with the use of Powder and Magnetic Field Assisted on Machining Aluminium 6061 Alloy with EDM

Abstract

Abstract Surface characteristics are the major challenges faced by the manufacturing industry when materials are machined with electrical discharge machining. Magnetic Field assisted powder mixed electrical discharge machining (MFAPM-EDM) is hybrid machining process which has shown the good potential of improving the surface characteristics. In this present paper, machining of aluminium 6061 alloy was carried out with aluminium powder mixed in EDM oil and in presence of magnetic field using EDM process Magnetic field, spark on duration, spark off duration, pulse current and powder concentration were selected as variable machining parameters and surface roughness as a response. Box-Behnken design approach based on response surface methodology was used for performing the experiments. In the present analysis, current was observed as the most significant parameter followed by spark on duration, powder concentration and magnetic field on surface roughness. Improvement in surface roughness with lesser voids and craters were observed under the influence of magnetic field and aluminium powder mixed in EDM oil.