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<p>Electrical discharge machining (EDM) is extensively utilised for machining hard-to-cut materials, such as Inconel 825. However, its widespread industrial adoption is impeded by two major challenges such as low material removal rate (MRR) and poor surface integrity. Inefficient debris evacuation during machining is a major factor contributing to low MRR and poor surface quality. This work introduces an integrated approach by combining a novel work rotation technique and an interior flushing (IF) system to solve the issue of insufficient debris evacuation. Nano-silicon carbide (SiC) powder mixed deionised water is used as the dielectric fluid for this study. A comparative analysis has also been conducted among the three flushing techniques, such as side flushing (SF) with or without rotation and interior flushing (IF) with rotation. The investigation examines the effect of current and powder concentration on key performance parameters such as MRR, tool wear rate (TWR), and surface roughness (Ra) at a constant work rotational speed of 300&#xa0;rpm. The results indicate that increasing discharge current consistently enhances MRR, TWR, and Ra across all approaches. Incorporating SiC powder into the dielectric significantly enhances performance, resulting in maximum improvements of 50.1% in MRR, 5.2% in TWR, and 6.2% in Ra at a concentration of 1&#xa0;g/L. Among all the integrated approaches, the IF with rotation approach outperforms both SF with or without rotation approaches, yielding up to 40.6% and 8.2% higher MRR and 13.6% and 5.5% lower Ra, respectively. In terms of TWR, conventional SF produced better results compared to the other two approaches. The results of the ANOVA analysis reveal that all three input parameters, namely current, powder concentration, and flushing approaches, have a statistically significant effect (<i>p</i> &lt; 0.05) on each of the output responses. Additionally, field emission scanning electron microscopy (FESEM) analysis of the machined surfaces confirms that the IF with rotation approach results in improved surface quality with minimal resolidified materials and unflushed debris.</p>

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Performance Analysis of Nano-SiC Mixed EDM Process with Rotary Workpiece and Interior Flushing Tool During the Machining of Inconel 825

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • Md Piyar Uddin,
  • Arindam Majumder,
  • John Deb Barma

摘要

Electrical discharge machining (EDM) is extensively utilised for machining hard-to-cut materials, such as Inconel 825. However, its widespread industrial adoption is impeded by two major challenges such as low material removal rate (MRR) and poor surface integrity. Inefficient debris evacuation during machining is a major factor contributing to low MRR and poor surface quality. This work introduces an integrated approach by combining a novel work rotation technique and an interior flushing (IF) system to solve the issue of insufficient debris evacuation. Nano-silicon carbide (SiC) powder mixed deionised water is used as the dielectric fluid for this study. A comparative analysis has also been conducted among the three flushing techniques, such as side flushing (SF) with or without rotation and interior flushing (IF) with rotation. The investigation examines the effect of current and powder concentration on key performance parameters such as MRR, tool wear rate (TWR), and surface roughness (Ra) at a constant work rotational speed of 300 rpm. The results indicate that increasing discharge current consistently enhances MRR, TWR, and Ra across all approaches. Incorporating SiC powder into the dielectric significantly enhances performance, resulting in maximum improvements of 50.1% in MRR, 5.2% in TWR, and 6.2% in Ra at a concentration of 1 g/L. Among all the integrated approaches, the IF with rotation approach outperforms both SF with or without rotation approaches, yielding up to 40.6% and 8.2% higher MRR and 13.6% and 5.5% lower Ra, respectively. In terms of TWR, conventional SF produced better results compared to the other two approaches. The results of the ANOVA analysis reveal that all three input parameters, namely current, powder concentration, and flushing approaches, have a statistically significant effect (p < 0.05) on each of the output responses. Additionally, field emission scanning electron microscopy (FESEM) analysis of the machined surfaces confirms that the IF with rotation approach results in improved surface quality with minimal resolidified materials and unflushed debris.