Influence of Al Powder on Circularity During Micro-Electro-Discharge Machining of Monel K-500

Abstract

In the present era, μ-EDM is a promising non-conventional micro-machining process for drilling as well as cutting of electrically conductive materials in the micron range. The objectives of the present research work is to investigate the influence of various parameters such as peak current, pulse ON-time, working time, and aluminium powder concentration on circularity and to find out the significant process parameters based on Taguchi method during micro hole drilling on Monel K-500 with the help of an EDM set-up. Further, a mathematical model has been developed to correlate the relationship between process parameters and circularity based on Response Surface Methodology (RSM). Circularity is increased from 1 to 1.5 A of peak current, from 0.5 to 1.5 sec of working time and from 1 to 4 gm/lit of aluminium concentration. The maximum value of circularity is obtained as 0.976 at the parametric combination of 1.2 A of peak current, 1.8 sec of working time and 3.33 (gm/lit) of Al powder concentration.