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<p>Silicon carbide (SiC) powder mixed electric discharge machining (EDM) is a vital component in the efficient machining and manufacturing of numerous superalloys for the chemical, aerospace and marine sectors. The present article evaluates the effect of SiC powder mixed rotary-assisted EDM (SiC-R-EDM) on the machining characteristics of Monel 400, in terms of material removal rate (MRR), overcut (OC) and surface roughness (SR). A comparative analysis is performed through scanning electrons microscope (SEM) imaging to investigate the effect of SiC powder in EDM. An improvement of 29.5% in MRR, 13.16% in OC and 11.13% in SR was observed with the mixing of SiC powder in EDM. Assistance of tool rotations enhanced the discharge energy distribution in the machining regions.&#xa0;Response surface methodology (RSM) design was used to design the experiments, using “tool rotation speed,” “peak current,” “powder concentration” and “pulse-on time” as the input parameters. The ideal parametric combination, as determined by the desirability function (<i>d</i> = 0.893), obtained was: “powder concentration” of 6&#xa0;g/L, “tool rotation” of 90&#xa0;rpm, “peak current” of 4 A and “pulse-on time” of 4&#xa0;μs for maximizing the MRR and minimizing the OC and SR. These optimized parameters improved MRR by 26.82%, OC by 23.85% and SR by 30.76% as compared to the initial conditions.</p>

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Enhancing Silicon Carbide Powder Mixed Rotary Electrical Discharge Machining Performance during Monel 400 Machining: Novel Combination

  • 期刊论文

  • 发表日期：

    2025年5月8日

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  • Saurabh Bhardwaj,
  • C. S. Jawalkar,
  • Suman Kant,
  • Viveksheel Rajput

摘要

Silicon carbide (SiC) powder mixed electric discharge machining (EDM) is a vital component in the efficient machining and manufacturing of numerous superalloys for the chemical, aerospace and marine sectors. The present article evaluates the effect of SiC powder mixed rotary-assisted EDM (SiC-R-EDM) on the machining characteristics of Monel 400, in terms of material removal rate (MRR), overcut (OC) and surface roughness (SR). A comparative analysis is performed through scanning electrons microscope (SEM) imaging to investigate the effect of SiC powder in EDM. An improvement of 29.5% in MRR, 13.16% in OC and 11.13% in SR was observed with the mixing of SiC powder in EDM. Assistance of tool rotations enhanced the discharge energy distribution in the machining regions. Response surface methodology (RSM) design was used to design the experiments, using “tool rotation speed,” “peak current,” “powder concentration” and “pulse-on time” as the input parameters. The ideal parametric combination, as determined by the desirability function (d = 0.893), obtained was: “powder concentration” of 6 g/L, “tool rotation” of 90 rpm, “peak current” of 4 A and “pulse-on time” of 4 μs for maximizing the MRR and minimizing the OC and SR. These optimized parameters improved MRR by 26.82%, OC by 23.85% and SR by 30.76% as compared to the initial conditions.