The Effect of Nickel Micro Powder Suspended Dielectric on EDM Performance Measures of EN-19 Steel

In this study, a Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) study on the Powder Mixed Electrical Discharge Machining (PMEDM) of EN-19 (AISI-4140) steel has been carried out. Response Surface Methodology (RSM) has been used to plan and analyze the experiments. Peak current, pulse on time, diameter of electrode and concentration of micro-nickel powder added into dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance in terms of MRR, TWR and SR. Experiments have been performed on newly designed experimental setup developed in laboratory. Most important parameters affecting selected performance measures have been identified and optimum process conditions have been found. Also recommended optimal conditions have been verified by conducting confirmation experiments.