OPTIMIZATION OF SURFACE ROUGHNESS IN AISI D-3 MACHINING USING POWDER-MIXED ELECTRICAL DISCHARGE MACHINING WITH ALUMINUM POWDER

Nguyen Huu Phan, Shailesh Shirguppikar, Vaibhav Ganachari, Ly Nguyen Trong and Toan Nguyen Duc
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Nguyen Huu Phan: Department of Mechanical Technology, School of Mechanical and Automotive Engineering, Hanoi University of Industry, No. 298, CauDien Street, Bac TuLiem District, Hanoi 100000, Vietnam
Shailesh Shirguppikar: Department of Mechatronics Engineering, Rajarambapu Institute of Technology, Shivaji University, Sakharale, MS 414415, India
Vaibhav Ganachari: Department of Mechatronics Engineering, Rajarambapu Institute of Technology, Shivaji University, Sakharale, MS 414415, India
Ly Nguyen Trong: Department of Mechanical Technology, School of Mechanical and Automotive Engineering, Hanoi University of Industry, No. 298, CauDien Street, Bac TuLiem District, Hanoi 100000, Vietnam
Toan Nguyen Duc: School of Mechanical Engineering, Ha Noi University of Science and Technology, No. 1 Dai Co Viet Stress, Hai Ba Trung District, Hanoi City 100000, Vietnam

Surface Review and Letters (SRL), 2025, vol. 32, issue 08, 1-9

Abstract: This study investigates the impact of powder-mixed electrical discharge machining (PMEDM) with aluminum powder on surface roughness (SR), benchmarking its performance against traditional electrical discharge machining (EDM). This research demonstrates a significant enhancement in SR through the incorporation of aluminum powder into the dielectric fluid. A detailed analysis was conducted to evaluate the effects of critical process parameters — current (I), voltage (GV), powder concentration (PC), pulse duration (CT), and duty factor (DF) — on SR. The findings reveal that I, GV, and PC have a pronounced influence on SR, while CT and DF exhibit minimal effects. Optimal machining conditions were established as I=6 A, GV=55 V, CT=40μs, PC=3 g/L, and DF=7, achieving an impressive SR of 2.78 μm. Additionally, this study analyzed the thickness of the metal recast layer, which ranged from 1 μm to 25 μm. Notably, mixtures of aluminum and silicon carbide powders resulted in thicker recast layers compared to single powder setups. This research highlights the potential of PMEDM to enhance machining outcomes and identifies existing limitations in the tested parameters. It suggests future studies exploring alternative dielectrics, powder materials, and workpiece combinations to further refine PMEDM performance and broaden its industrial applicability.

Keywords: Powder-mixed electrical discharge machining; surface roughness; AISI D-3 steel; aluminum powder; optimization (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X2540013X

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