A Brief Review of Experimental Investigations and Analytical Development of Powder Mixed Electric Discharge Machining (PMEDM)

Abstract:

Powder mixed electric discharge machining (PMEDM) is a newly developed technology in which EDM is performed by mixing electrically conductive micro or nanoparticles with dielectric fluid. The electrically conductive tiny particles when come at the gap of electrode and work piece, they will begin to create spark by the induction of electrode voltage which enhances the material removal and surface finish of the machined surface. In this paper a brief review has been done on different aspects of powder mixed electric discharge machining. It is observed that the researches are done in three main directions. Firstly, experimental studies are done to show the effect of several input process parameters on responses mainly material removal rate (MRR), surface roughness and tool wear rate. Secondly, the metallurgical characteristics of the machined surface are analyzed to measure the white layer thickness and amount of powder material inclusion onto the surface. The third one is the investigation of thermal characteristics of the tool and work pieces during the machining process. In these three sections of researches, the results of the investigations have been discussed in this review. Keywords: powder mixed electric discharge machining, metallurgical characteristics, nano particles, material removal rate, surface roughness, tool wear rate, white layer thickness, thermal characteristics

• Periodical: Advances in Science and Technology (Volume 106)
• Pages: 31-38
• DOI: https://doi.org/10.4028/www.scientific.net/AST.106.31
• Online since: May 2021
• Authors: Sovan Bhowmick*, Gautam Majumdar, Asish Bandyopadhyay
• Keywords: Material Removal Rate, Metallurgical Characteristics, Nano Particles, Powder Mixed Electric Discharge Machining, Surface Roughness, Thermal Characteristics, Tool Wear Rate, White Layer Thickness

References

[1] Kumar A, Kumar S, Mandal A, Dixit AR. Investigation of powder mixed EDM process parameters for machining Inconel alloy using response surface methodology. Materials Today: Proceedings 2018;5,6183–6188.

DOI: 10.1016/j.matpr.2017.12.225

[2] Kansal HK, Singh S, Kumar P. Parametric optimization of powder mixed electrical discharge machining by response surface methodology. Journal of Materials Processing Technology 2005;169,427–436.

DOI: 10.1016/j.jmatprotec.2005.03.028

[3] Singh P, Kumar A, Beri N, Kumar V. Some experimental investigation on aluminum powder mixed EDM on machining performance of hastelloy steel. International Journal of Advanced Engineering Technology 2010;1,28-45.

[4] Singh S, Yeh MF. Optimization of Abrasive Powder Mixed EDM of Aluminum Matrix Composites with Multiple Responses Using Gray Relational Analysis. Journal of Materials Engineering and Performance 2012;21,481-491.

DOI: 10.1007/s11665-011-9861-z

[5] Roy C, Syed KH, Kuppan P. Machinablity of Al/ 10%SiC/ 2.5%TiB2 metal matrix composite with powder-mixed electrical discharge machining. Procedia Technology 2016;25,1056 – 1063.

DOI: 10.1016/j.protcy.2016.08.206

[6] Modica F, Marrocco V, Valori M, Viganò F, Annoni M, Fassi I. Study about the Influence of powder mixed water based fluid on micro-EDM process. Procedia CIRP 2018;68,789 – 795.

DOI: 10.1016/j.procir.2017.12.156

[7] Talla G, Gangopadhyay S, Biswas CK. Multi response optimiztion of powder mixed electric discharge machining of aluminum/alumina metal matrix composites using grey relation analysis. Procedia Materials Science 2014;5, 633 – 1639.

DOI: 10.1016/j.mspro.2014.07.351

[8] Talla G, Sahoo DK,Gangopadhyay S, Biswas CK. Modeling and multi-objective optimization of powder mixed electric discharge machining process of aluminum/alumina metal matrix composite. Engineering Science and Technology, an International Journal 2015;18, 69-373.

DOI: 10.1016/j.jestch.2015.01.007

[9] Chaudhury P, Samantaray S, Sahu S. Multi Response Optimization of Powder Additive Mixed Electrical Discharge Machining by Taguchi Analysis. Materials Today: Proceedings 2017;4,2231–2241.

DOI: 10.1016/j.matpr.2017.02.070

[10] Chaudhury P, Samantaray S. Role of Carbon Nano Tubes in Surface Modification on Electrical Discharge Machining -A Review. Materials Today: Proceedings 2017;4,4079–4088.

DOI: 10.1016/j.matpr.2017.02.311

[11] Tripathy S, Tripathy DK, Multi-attribute optimization of machining process parameters in powder mixed electro-discharge machining using TOPSIS and grey relational analysis. Engineering Science and Technology, an International Journal 2016;19,62–70.

DOI: 10.1016/j.jestch.2015.07.010

[12] Singh B, Kumar J, Kumar S. Influences of Process Parameters on MRR Improvement in Simple and Powder Mixed EDM of AA6061/10%SiC Composite. Materials and Manufacturing Processes 2014;1-42.

DOI: 10.1080/10426914.2014.930888

[13] Mohal S, Kumar H. Study on the Multi walled Carbon Nano tube Mixed EDM of Al-SiC Metal Matrix Composite. Materials Today: Proceedings 2017;4,3987–3993.

DOI: 10.1016/j.matpr.2017.02.299

[14] Bhattacharya A, Batish A, Singh G, Singla VK. Optimal parameter settings for rough and finish machining of die steels in powder-mixed EDM. International Journal of Advanced Manufacturing Technology 2012;61,537-548.

DOI: 10.1007/s00170-011-3716-5

[15] Jarin S, Saleh T, Rana M , Muthalif AGA, Ali MY. An experimental investigation on the effect of nanopowder for Micro-Wire Electro Discharge Machining of gold coated silicon. Procedia Engineering 2017;184,171 – 177.

DOI: 10.1016/j.proeng.2017.04.082

[16] Marashi H, Sarhan AAD, Hamdi M. Employing Ti nano-powder dielectric to enhance surface characteristics in electrical discharge machining of AISI D2 steel. Applied Surface Science 2015;357,892–907.

DOI: 10.1016/j.apsusc.2015.09.105

[17] Marashi H, Jafarlou DM, Sarhan AAD, Hamdi M. State of the art in powder mixed dielectric for EDM applications. Precision Engineering 2016;46,11-33.

DOI: 10.1016/j.precisioneng.2016.05.010

[18] Singh G, Singh G, Singh K, Singla A. Experimental studies on material removal rate, tool wear rate and surface properties of machined surface by powder mixed electric discharge machining. Materials Today: Proceedings 2017;4,1065–1073.

DOI: 10.1016/j.matpr.2017.01.121

[19] Hu FQ, Cao FY, Song BY, Hou PJ, Zhang Y, Chen K, Wei JQ. Surface properties of SiCp/Al composite by powder-mixed EDM. Procedia CIRP 2013;6,101 – 106.

DOI: 10.1016/j.procir.2013.03.036

[20] Peng H, Yu D, Zhang X, Wang S, Wen Y. Fabrication of hollow nickel micro-spheres with high degree of hollowness by silicon powder-mixed spark erosion. International Journal of Machine Tools & Manufacture 2014;85,131–134.

DOI: 10.1016/j.ijmachtools.2014.06.002

[21] Kolli M, Kumar A. Effect of dielectric fluid with surfactant and graphite powder on Electrical Discharge Machining of titanium alloy using Taguchi method. Engineering Science and Technology, an International Journal 2015;18,524-535.

DOI: 10.1016/j.jestch.2015.03.009

[22] Liew PJ, Yan J, Kuriyagawa T. Carbon nanofiber assisted micro electro discharge machining of reaction-bonded silicon carbide. Journal of Materials Processing Technology 2013; 213, 1076–1087.

DOI: 10.1016/j.jmatprotec.2013.02.004

[23] Bains PS, Sidhu SS, Payal SS, Kaur S. Magnetic Field Influence on Surface Modifications in Powder Mixed EDM, Silicon 2018;11,415-423.

DOI: 10.1007/s12633-018-9907-z

[24] Ou SF, Wang CY. Effects of bioceramic particles in dielectric of powder-mixed electrical discharge machining on machining and surface characteristics of titanium alloys. Journal of Materials Processing Technology 2017;245,70–79.

DOI: 10.1016/j.jmatprotec.2017.02.018

[25] Yih-fong TY, Chen CF. Investigation into some surface characteristics of electrical discharge machined SKD-11 using powder-suspension dielectric oil. Journal of Materials Processing Technology 2005;170,385–391.

DOI: 10.1016/j.jmatprotec.2005.06.006

[26] Wong YS, Lim LC, Rahuman I, Tee WM. Near-mirror-finish phenomenon in EDM using powder-mixed dielectric. Journal of Materials Processing Technology 1998;79,30–40.

DOI: 10.1016/s0924-0136(97)00450-0

[27] Xie ZJ, Mai YJ, Lian WQ, He SL, Jie XH. Titanium carbide coating with enhanced tribological properties obtained by EDC using partially sintered titanium electrodes and graphite powder mixed dielectric. Surface & Coatings Technology 2016;300,50–57.

DOI: 10.1016/j.surfcoat.2016.04.080

[28] Han M, Min B, Lee SJ, Improvement of surface integrity of electro-chemical discharge machining process using powder-mixed electrolyte. Journal of Materials Processing Technology 2007; 191, 224–227.

DOI: 10.1016/j.jmatprotec.2007.03.004

[29] Jatti VS, Bagane S. Thermo-electric modelling, simulation and experimental validation of powder mixed electric discharge machining (PMEDM) of BeCu alloys, Alexandria Engineering Journal 2018; 57(2), 643-653.

DOI: 10.1016/j.aej.2017.02.023

[30] Kim YS, Chu CN. The Effects of Graphite Powder on Tool Wear in Micro Electrical Discharge Machining. Procedia CIRP 2018;68,553 – 558.

DOI: 10.1016/j.procir.2017.12.121

[31] Khazraji A, Amin SA, Ali SM. The effect of SiC powder mixing electrical discharge machining on white layer thickness, heat flux and fatigue life of AISI D2 die steel. Engineering Science and Technology 2016, 19, 1400-1415.

DOI: 10.1016/j.jestch.2016.01.014