Machining performance enhancement of EN-31 diesteel using MWCNT mixed rotary EDM

Bajaj, Rajesh ; Dixit, Amit Rai; Tiwari, Arun Kumar; Chauhan, Nitin Kumar

Abstract

The present study investigates the influence of adding multi-wall carbon nanotube (MWCNT) into the dielectric fluid of electric discharge machining (EDM) in terms of material removal rate (MRR), surface roughness (SR) and surface topology of EN-31 die steel using Cu electrode. A customized rotary electrode set-up has been developed to compare the performance improvement of powder mixed rotary electrical discharge machining (PMREDM) as compared to powder mixed electrical discharge machining (PMEDM) and conventional EDM. The present study attempts to investigate the optimization of process parameters of MWCNT mixed rotary EDM of EN-31 die steel using response surface methodology (RSM) and genetic algorithm (GA) in terms of MRR and SR. The optimization results show that MWCNT mixed rotary EDM shows highest value of MRR (9.72 mm3/min) and lowest value of SR (Ra = 2.03 μm), which are approximately 46.17% higher and 45.43% lower than conventional EDM values respectively. Further, various combinations of optimal values of MRR and SR and their corresponding input parameters setting have been shown in pareto table created by multi-objective optimization GA technique available in MATLAB. Finally, field emission scanning electron microscope (FESEM) analysis of MWCNT mixed rotary EDM and EDM surfaces is carried out which revealsthat MWCNT mixed rotary EDM shows better surface topography as compared to EDM process.

Keyword(s)

Material removal rate, Surface roughness, Genetic algorithm, Powder mixed electric discharge machining, FESEM, Micro cracks, Response surface methodology

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