A literature review on Process parameter optimization of Powder Mixed Electric Discharge Machining (PMEDM) using design of experiment

EDM is a non- conventional machining process in which the material is removed by erosive effect. Arc is established between the electrode and tool both should be electrical conductive. There is no direct contact between the two. It is useful for machining hard, difficult to machine materials such as heat resistant alloys, super alloys and carbides which can�t be easily machined with conventional once. Its unique feature of using thermal energy to machine electrically conductive parts regardless of its hardness. It is commonly used in mould, die making industry and in manufacturing of automotive, aero-space surgical components. However, EDM suffers few limitations such as low machining efficiency and poor surface finish. To overcome these limitations the electrically conductive powder particles are mixed in the dielectric fluid, which reduces its insulating strength and increases the spark gap distance between the tool and workpiece. This new hybrid material removal process is called Powder mixed EDM (PM-EDM). From the point of view of industrial applications, die steel is a very important material and that�s why for the purpose of experimentation D3 die steel with copper electrode and IPOL oil as dielectric has been used. PMEDM is very complex in nature and controlled by a large number of parameters, which are having impact on various responses. The present study is an attempt to investigate the potential of PMEDM for increasing material removal rate (MRR), decrease in tool wear rate (TWR) with improved surface roughness (SR) of Die steel. In previous research work Kerosene is used as dielectric fluid. Kerosene has adverse impact on the environment as well as health of the operator. So in this experimental method commercially available EDM oil will be used. The research outcome will identify the important parameters and their effect on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) in the presence of suspended powder in a IPOL oil as dielectric of EDM. Experiments is designed using Design of Experiment so that effect of all the parameters could be studied with minimum possible number of experiments. Results of the experimentation is analyze analytically as well as graphically using ANOVA and main effect-interaction plots, respectively. ANOVA has determined the percentage contribution of all factors upon each response individually.