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<p>The addition of graphene to aluminium (Al) matrices has garnered significant attention for machining operations and EDM toolmaking. In this study, the primary objective was to explore the behaviour of Graphene-reinforced Al metal matrix composites (Gr-Al MMCs) during the EDM process when used as tool material on EN 31 die steel workpiece. Gr-Al MMCs was prepared using powder metallurgy, with graphene incorporated in three different compositions (0.5%, 1%, and 1.5% by weight), along with copper (5% by weight) and silicon carbide (2% by weight). These materials were processed using the Taguchi L9 orthogonal array into cylindrical shapes of 19&#xa0;mm in length and 10&#xa0;mm in diameter, forming nine different samples. Each of the sample was employed in experimentation for every run of the EDM die sinking operation, utilizing the above tool-workpiece combination. SEM images were taken using a Scanning Electron Microscope (HITACHI S-3400&#xa0;N) which shows micro voids and recast layers in the microstructure of the tool and the workpiece. By employing Taguchi L9 design of experiments and Signal to Noise ratio analysis, optimal EDM parameters were identified: low current-I<sub>p</sub> (1 amp), medium pulse-on time-T<sub>on</sub> (75 µs), and low gap voltage-S<sub>v</sub> (30&#xa0;V) for minimum tool wear, while a medium gap voltage (40&#xa0;V) yielded maximum Material Removal Rate (MRR).</p>

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Electric Discharge Machining with Graphene Reinforced Aluminium Metal Matrix Composite (Gr Al MMC) Tool for EN 31 Die Steel Work Piece

  • 期刊论文

  • 发表日期：

    2025年1月25日

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  • Subrata Mondal,
  • Goutam Paul,
  • Koustov Mondol,
  • Subhas Chandra Mondal

摘要

The addition of graphene to aluminium (Al) matrices has garnered significant attention for machining operations and EDM toolmaking. In this study, the primary objective was to explore the behaviour of Graphene-reinforced Al metal matrix composites (Gr-Al MMCs) during the EDM process when used as tool material on EN 31 die steel workpiece. Gr-Al MMCs was prepared using powder metallurgy, with graphene incorporated in three different compositions (0.5%, 1%, and 1.5% by weight), along with copper (5% by weight) and silicon carbide (2% by weight). These materials were processed using the Taguchi L9 orthogonal array into cylindrical shapes of 19 mm in length and 10 mm in diameter, forming nine different samples. Each of the sample was employed in experimentation for every run of the EDM die sinking operation, utilizing the above tool-workpiece combination. SEM images were taken using a Scanning Electron Microscope (HITACHI S-3400 N) which shows micro voids and recast layers in the microstructure of the tool and the workpiece. By employing Taguchi L9 design of experiments and Signal to Noise ratio analysis, optimal EDM parameters were identified: low current-Ip (1 amp), medium pulse-on time-Ton (75 µs), and low gap voltage-Sv (30 V) for minimum tool wear, while a medium gap voltage (40 V) yielded maximum Material Removal Rate (MRR).