Experimental investigation of machining of EN31 Steel in abrasive mixed rotary EDM with graphite and copper electrode
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The present work proposes an integration of tool rotation and blending of silicon carbide powder with kerosene as dielectric fluid in electrical discharge machining of EN31 steel with graphite and copper electrode. Peak current, pulse on time and tool rotation were identified as the machining parameters to evaluatetheir effect on material removal rate, tool wear rate and surface roughness of EN31 steel. Full factorial experimentation was executed to study 3 factors at 3 levels. Surface morphology of workpiece and powder characteristics were studied and analysed with FESEM, EDS and XRD techniques. Furthermore, recast layer thickness and sub-surface microhardness of the workpiece were examined to evaluate micro-changes in the performance characteristics. The recast layer thickness achieved by the graphite electrode was 6.12 μm whereas,copper achieved a value of 32.29 μm in the proposed method. The proposed process enhanced the sub-surface microhardness from 514.59 HV0.5 to 533.23 HV0.5 with graphite electrode, and from 503.55 HV0.5 to 523.54 HV0.5 with copper electrode, respectively. Genetic algorithm was executed to perform multi-objective optimization.
Volume 48, 2023
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