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Effect of powder concentration on EDM performance during machining mild steel

Khan, Ahsan Ali and Wahid Azmi, Nurfarah and Odenan, Mohd Azim and Mohd Zain, Zakaria (2015) Effect of powder concentration on EDM performance during machining mild steel. Advanced Materials Research, 1115. pp. 7-11. ISSN 1662-8985

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This research work describes the effect of powder concentration in dielectric fluid during electrical discharge machining (EDM) of mild steel on material removal rate (MRR), electrode wear rate (EWR) and work surface roughness (Ra). The machining parameters studied in this research are current (4.5A, 5.5A, and 6.5A) and concentration of the powder (30g/l, 60g/l, and 90g/l). It was decided to use copper (Cu) as the electrode, mild steel as the work material and tantalum carbide (TaC) as the powder to be mixed with the dielectric. Design-Expert software was used to design and analyze the experiments. The performance of machining was analyzed and it was found that powder concentration does not have much effect on MRR or work surface roughness (Ra). At low current powder concentration reduces electrode wear rate (EWR), but at higher current the situation is opposite. It was also found that in all conditions, MRR and EWR increases with increase in current. A higher current produces stronger spark with higher energy that melts more materials from the workpiece and the electrode. As a result both MRR and EWR increases and job surface becomes poor.

Item Type: Article (Journal)
Additional Information: 3129/44177
Uncontrolled Keywords: EDM, Electrode Wear, Material Removal Rate (MRR), Powder Concentration
Subjects: T Technology > TS Manufactures > TS200 Metal manufactures. Metalworking
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button): Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering
Depositing User: Prof. Dr. Ahsan Ali Khan
Date Deposited: 05 Aug 2015 08:47
Last Modified: 25 Nov 2017 09:03
URI: http://irep.iium.edu.my/id/eprint/44117

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