An Experimental Study on Parametric Optimization of High Carbon Steel (EN-31) by using Silicon Powder Mixed Dielectric EDM Process

Powder mixed electric discharge machining (PMEDM) is a recent innovation for enhancing the capabilities of electrical discharge machining process. The objective of present study is to realize the potential of silicon powder as additive in enhancing machining capabilities of PMEDM on EN31. Taguchi methodology has been adopted to plan and analyze the experimental results. L16 Orthogonal Array has been selected to conduct experiments. Peak current, Pulse on time, Pulse off time, gap voltage, and concentration of fine silicon powder added into the dielectric fluid were chosen as input process variables to study performance in terms of material removal rate& surface roughness. The ANOVA analysis identifies the most important parameters to maximize material removal rate& minimize surface roughness. The recommended best parametric settings have been verified by conducting confirmation experiments. From the present experimental study it is found that addition of silicon powder enhances machining rate& surface roughness appreciably.