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In the present work, Aluminum Alloy 6061/10%SiC composite is machined using ZNC electrical discharge machining (EDM) process. Improvement in material removal rate (MRR) is explored using tungsten powder suspended dielectric fluid in EDM process (PMEDM). Peak current, pulse on time, pulse off time and gap voltage are studied as process parameters. Mathematical relation between process parameters and MRR is established on basis of Response Surface Methodology (RSM). The results obtained are further compared with MRR achieved from machining using simple EDM. The existence of tungsten particles in kerosene resulted 48.43% improvement in MRR. The influence of tungsten powder mixed dielectric fluid on machined surface are analyzed using Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS). The results revealed improvement in surface finish and reduction in recast layer thickness with PMEDM. EDS analysis reported presence of tungsten and carbon in recast layer deposited on machined surface.

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In this work, quantitative assessment of surface damage in terms of parameters like surface crack density and recast layer thickness in wire electrical discharge machining (WEDM) process has been undertaken. The effect of processing conditions on crack formation is studied using scanning electron microscope. Surface crack density and recast layer thickness analysis in terms of machining parameters such as pulse on time, pulse off time, peak current, spark gap voltage significantly deteriorate the microstructure of machined samples, which produces the deeper, wider overlapping craters, pock marks, globules of debris and micro cracks. The microstructure analysis of WEDM surface was based upon the theory of electrical discharge phase and metallurgical physics. It is found that the pulse on time, pulse off time and peak current are the most dominating parameters for both surface crack density and recast layer thickness.

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