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Performance Analysis and Optimization of Different Electrode Materials and Dielectric Fluids on Machining of High Carbon High Chromium Steel in Electrical Discharge Machining

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Proceedings of the National Academy of Sciences, India Section A: Physical Sciences Aims and scope Submit manuscript

Abstract

The present paper presents an experimental study on the performance evaluation of different electrode materials and dielectric fluids on high carbon high chromium (HcHcr) tool steel in electric discharge machining (EDM). Dielectric fluids (kerosene, distilled water, and EDM oil), electrode materials (copper, brass, and graphite) with current and pulse-on time are considered as input parameters while material removal rate (MRR), and surface roughness (Ra) as output parameters. HcHcr tool steel is used as work material due to its extensive use in aerospace, automotive, and tooling industries. Experiments are performed using Taguchi (L29) orthogonal array. Additionally, ANOVA analysis is performed to determine the most influencing parameters on the output. The results show that the electrode material is most influential for MRR, while dielectric fluid for Ra. Optimal setting obtained for MRR is electrode material (graphite), peak current (9 A), pulse-on time (50 µs), and dielectric (kerosene) and for Ra is electrode material (copper), peak current (3 A), pulse-on time (50 µs) and dielectric (kerosene). Similarly, the overall optimization is done via multi-objective optimization on the basis of ratio analysis method and optimal parameter setting obtained with graphite electrode, peak current (10 A), pulse-on-time (50 µs), and distilled led water as dielectric fluid. The microstructure of the machined surface is taken by scanning electron microscope to study the surface integrity and results revealed that smooth and uniform distribution of surface during the machining of HcHcr tool steel in EDM.

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Acknowledgements

The authors acknowledge to Dr.S.K.Jain, Head of Mechanical Engineering Department, Ambala College of Engg and Applied Research, Mithapur, Harayana, India, for providing the necessary resources and other facilities during the research work and Also, thanks to Prof.Ishwar Chander Ramola and Prof.Narendra Kumar, Assistant Professor, Department of Mechanical Engineering, Ambala College of Engg and Applied Research, Mithapur, Ambala, Haryana, India, for his valuable guidance during experimentation.

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  1. Department of Mechanical Engineering, National Institute of Technology Raipur, Raipur, India

    Jagadish & Dheeraj Lal Soni

  2. Department of Mechanical Engineering, Bengal College of Engineering and Technology, Durgapur, India

    Sandeep Kumar

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Jagadish, Kumar, S. & Soni, D.L. Performance Analysis and Optimization of Different Electrode Materials and Dielectric Fluids on Machining of High Carbon High Chromium Steel in Electrical Discharge Machining. Proc. Natl. Acad. Sci., India, Sect. A Phys. Sci. 92, 273–284 (2022). https://doi.org/10.1007/s40010-020-00727-4

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