Analysis and Modeling of Tool Wear Rate in Powder Mix EDM and Pure EDM Using Central Composite Design

Abstract

The process of using dielectric fluid combined with different types of powders to improve the output of the machined surface is known as powder-mixed electrical discharge machining (PMEDM). In the electrical discharge machining (EDM) industry, this procedure is quickly gaining popularity. This investigation's goal is to ascertain whether tantalum carbide (TaC) powder-mixed dielectric fluid can reduce tool wear during the subsequent EDM machining of stainless-steel material. Two different EDM medium's tool wear rates and mathematical models were investigated during the machining. TaC powder at a concentration of 25.0 g/L in kerosene dielectric fluid was used for the machining process. The peak current, pulse on time, and pulse off time were the machining variables used. These variables' effects on the copper based EDMed electrode tools TWR were identified. The TWR for stainless steel (SUS 304) during electrical discharge machining was reduced by 37.9% when TaC powder additive was used, according to the results, demonstrating the effectiveness of this alternative method for reducing tool wear. The most influential factor, according to the tool wear ratio model for EDM with TaC powder additive (TWRPMEDM), is current, followed by pulse on-time and pulse off-time.