Title: Comparative study of powder mixed EDM and rotary tool EDM performance during machining of Al-SiC metal matrix composites

Authors: Umesh Kumar Vishwakarma; Akshay Dvivedi; Pradeep Kumar

Addresses: Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee, UK, 247667, India ' Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee, UK, 247667, India ' Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee, UK, 247667, India

Abstract: Electrical discharge machining (EDM) is used for machining of any electrically conductive materials irrespective of their hardness. A number of EDM process variants have been developed over the years for improving the machining performance. Powder mixed EDM (PMEDM) and rotary tool EDM (REDM) are such process variants which have improved the efficiency of the machining process. In the present study, a comparative study of the effect of various process parameters were carried out on PMEDM and REDM process. The output characteristics measured were the material removal rate (MRR) and the tool wear rate (TWR). Experimental results reveal that the MRR in PMEDM was higher as compared to conventional die-sinking EDM. However, average MRR of REDM process was about 2.5 times higher as compared to that of the PMEDM process. In PMEDM, the debris accumulation in the inter electrode gap limited the machining rate. In case of REDM, tool rotation improved the flushing efficiency.

Keywords: powder mixed EDM; PMEDM; rotary tool EDM; REDM; metal matrix composites; MMCs; material removal rate; MRR; tool wear rate; TWR; aluminium; silicon carbide; SiC; metal matrix composites; electrical discharge machining; EDM; electro-discharge machining; debris accumulation; inter electrode gap; tool rotation; flushing efficiency.

DOI: 10.1504/IJMMM.2014.064684

International Journal of Machining and Machinability of Materials, 2014 Vol.16 No.2, pp.113 - 128

Received: 21 Jan 2014
Accepted: 15 Mar 2014
Published online: 10 Sep 2014 *

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