PERFORMANCE OF ELECTRICAL DISCHARGE MACHINING (EDM) WITH NICKEL ADDED DIELECTRIC FLUID

AHSAN ALI KHAN; Muataz Hazza faizi Al Hazza

doi:10.31436/iiumej.v19i1.759

Authors

AHSAN ALI KHAN
Muataz Hazza faizi Al Hazza

DOI:

https://doi.org/10.31436/iiumej.v19i1.759

Abstract

In this study, the effect of nickel powder mixed dielectric fluid on Electrical Discharge Machining (EDM) performance of mild steel has been carried out. Peak current, tool/electrode diameter and concentration of powder are the process parameters. The process performance is measured in terms of material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The experiment has been designed using a Full Factorial in Design of Experiment (DOE) software. The research outcome is to identify the important process parameters that maximize MRR and minimize TWR and SR. The experiment has been carried out using 2 levels of current (3.5 A and 6.5 A), tool diameters (14 mm and 20 mm) and Nickel powder concentrations (0 g/l and 6 g/l). The weight of the mild steel work piece and copper electrode are measured before and after each run. Based on the results, current is the most significant parameter affecting MRR, TWR, and SR. It was also found that with added nickel powder in the dielectric fluid, the tool life is longer and surface roughness of the work piece is improved. Furthermore, it was shown that both MRR and TWR increased with the increase in tool diameter. However, SR was improved as tool diameter increased but its effect was not very significant.

ABSTRAK: Dalam kajian ini, mutu keberhasilan campuran serbuk nikel cecair dielektrik pada Sisa Mesin Elektrik (EDM) ke atas besi ringan telah dijalankan. Arus tertinggi, alat/diameter elektrod dan ketumpatan serbuk adalah parameter kawalan. Pencapaian proses diukur dari segi kadar penyingkiran bahan (MRR), kadar penggunaan alat (TWR) dan kekasaran permukaan (SR). Eksperimen ini direka bentuk dengan menggunakan perisian Faktorial Penuh dalam Rekaan Eksperimen (DOE). Hasil kajian ini adalah untuk mengidentifikasi kepentingan parameter kawalan yang mengoptimumkan MRR, meminimumkan TWR dan SR. Eksperimen ini dijalankan pada 2 peringkat arus elektrik (3.5 A dan 6.5 A), diameter alat (14 mm dan 20 mm) dan ketumpatan serbuk nikel (0 g/l and 6 g/l). Berat bahan uji seperti besi ringan dan elektrod tembaga diukur pada sebelum dan selepas setiap ujian. Berdasarkan keputusan, arus elektrik adalah faktor paling ketara yang mempengaruhi MRR, TWR, dan kekasaran permukaan. Turut didapati pada setiap pertambahan serbuk Nikel ke dalam cecair dielektrik, jangka hayat alat turut bertambah dan kekasaran permukaan pada bahan uji turut bertambah baik. Selain itu, kedua-dua MRR dan TWR bertambah dengan setiap pertambahan diameter alat. Sebaliknya, kekasaran permukaan bertambah baik dengan pertambahan diameter alat tetapi kesannya tidak ketara.

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