Investigating the performance of powder mixed electric discharge machining of Nimonic 75 by using different tool materials

Abstract

Purpose This study aims to focus on experimenting the performance of aluminum (Al) powder mixed electric discharge machining (PMEDM) of two different materials viz plastic mould die steel (AISI P20) and nickel-based super alloy (Nimonic 75). This experimental study also focuses on using three different tool materials such as copper, brass and tungsten to analyze their influence on the process output. These materials find many uses in industrial as well as aerospace applications. The performance measures considered in this work are material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR). Design/methodology/approach The experimental design used in this work is based on Taguchi’s L18 orthogonal array. Besides considering work and tool material as one of the process variables, other process variables are peak current (I p ), pulse on time (T on ) and concentration of powder (C p ). The analysis of variance (ANOVA) is performed on the experimental data to determine the significant variables that influence the output. Findings It is found that copper produced maximum MRR and brass tool exhibited higher TWR. However, the surface finish of the machined work piece was very much improved by using the brass tool. Though the performance of tungsten tool lies between the above two tool materials, it showed very little wear during EDM with or without the addition of Al powder. Originality/value The experimental investigation of PMEDM of nickel-based super alloy (Nimonic 75) has not been attempted before. Besides that, the study on the influence of tungsten tool on the performance of EDM is also very limited.