Performance Evaluation with Metallurgical Aspects on Groove Formation during Magnetic Field-Assisted Electrical Discharge Turning of EN24 Steel Alloy

This research studies the impact of magnetic field assistance in the electrical discharge turning (EDT) process during groove formation on EN24 Steel alloy. A turning attachment has been developed and attached to the existing EDM machine. Magnetic field assistance is also provided to the developed turning-EDM setup with the help of permanent magnets. By utilizing one parameter at a time methodology, the effects of gap current (Ig), pulse duration (T_on), rotational speed (N), and magnetic field (MF) strength have been investigated on material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness (R_a). The results reveal that magnetic field-induced Lorentz force enhances debris flushing and machining efficiency. MRR and TWR are notably increased by magnetic field assistance and influenced by process parameters. The presence of magnetic fields reduces OC and improves R_a through controlled spark channeling. SEM analysis also shows the significant impact of magnetic field assistance in enhancing the surface integrity of the material. Further, EDS and XRD analysis show improved surface properties, including reduced migration of carbon and refined structure with N42 MF assistance. The research emphasizes the potential of magnetic field-assisted EDT in enhancing surface integrity and quality during EN24 steel alloy machining.