Powder-mixed electrical discharge machining (PMEDM) is the technique of using dielectric fluid mixed with various types of powders to improve the machined surface output. This process is fast gaining prominence in electrical discharge machining (EDM) industry. The objective of this investigation is to determine the ability of tantalum carbide (TaC) powder-mixed dielectric fluid to enhance the surface properties of stainless steel material during EDM. The properties investigated are the micro-hardness and corrosion characteristics of the EDMed surface. Machining was conducted with 25.0 g/L concentration of TaC powder in kerosene dielectric fluid. The machining variables used were the peak current, pulse on time and the pulse off time. The effects of these variables on the micro-hardness of the EDMed surface were determined. Corrosion tests were also conducted on the samples that exhibited higher hardness. Results showed that the EDMed surface was alloyed with elements from the TaC powder. The highest micro-hardness obtained with PMEDM is about 1,200 Hv. This is about 1.5 times that obtained without TaC powder in the dielectric fluid. The loss in weight during corrosion test was found to be 0.056 µg/min for the PMEDM which was much lower than the lowest value of 10.56 µg/min obtained for the EDM without powder dielectric fluid.
Powder mixed electrical discharge machining (PMEDM) is one of the recent innovations for the enhancement of the capabilities of EDM process. In this study, the effects of powder addition on the surface modification of mild steel were investigated. Copper tungsten electrode was used in the machining. Two different powders namely TiC and Al2O3 were used in the study with kerosene as the dielectric medium. The powder types and currents were manipulated to study their effects on the machined surface. The results show that increasing the current leads to increase in recast layer thickness, and the cracks. The Al2O3 powder gave higher layer thickness than TiC powder. TiC Powder addition also produced higher hardness, more tool material and carbon depositions on the work surface than Al2O3 powder.
Powder-mixed dielectric fluid is one of the innovations of electro-discharge machining (EDM) which seeks to improve the process outputs by addition of powders to the dielectric during machining. In the present study, the influence of TaC powder in kerosene dielectric fluid on EDM process outputs was investigated. Experiments were conducted with the outputs as material removal rate (MRR), surface roughness (Ra) and micro-hardness. During the EDM, the discharge current was varied between 2.5 and 6.5 A, while powder concentration ranges between 5.0 and 15.0 g/l. Results indicate that the highest MRR of 0.38 g/min was obtained with TaC concentration of 15 g/l at the current of 6.5 A. TaC powder addition does not affect both the MRR and Ra at lower current. However, the level of micro-hardness attained was influenced by TaC powder concentration in dielectric fluid, the highest being 1,040 Hv with 5.0 g/l at the current of 2.5 A.
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