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<p>Low material removal, high tool wear rate, and surface defects are critical machining characteristics in the electrical discharge machining process that reduce machining efficiency. In the present study, a novel nitrogen (N<sub>2</sub>) gas–liquid mixed-based electrical discharge machining (EDM) technology was proposed to increase machining efficiency for machining of Inconel 718. A periodic bidirectional tool rotation was proposed in EDM for better circulation of dielectric fluid to the machining area. Experiments were conducted at three levels of current (4, 5, and 6 A), duty cycles (50%, 55%, and 60%), and gas pressures (0.015, 0.02, and 0.025&#xa0;MPa), and the surface roughness, metal removal rate, and microhardness were compared with EDM without N<sub>2</sub> gas. The periodic bidirectional rotation of the tool promoted the proper spreading of dielectric fluid along with the N<sub>2</sub> gas, thereby the debris were expelled out from the electrode gap and the metal removal rate increased with reduced surface defects. The metal removal rate and microhardness were improved by 31% and 68%, respectively, and the surface roughness was reduced by 42%. The process parameters were optimized using the particle swarm optimization technique and optimum parameters were found to be 7.403&#xa0;A of current, 45.407% of duty cycle, and 0.030&#xa0;MPa of gas pressure. Surface defects like blow holes, micropores, and surface cracks were reduced in the EDM with N<sub>2</sub> gas.</p>

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An experimental investigation on metal removal rate, surface roughness and microhardness in nitrogen gas–liquid mixed EDM

  • 期刊论文

  • 发表日期：

    2025年6月9日

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  • Gavireddy Sudharsan Reddy,
  • Kaki Venkata Rao,
  • Gamini Suresh

摘要

Low material removal, high tool wear rate, and surface defects are critical machining characteristics in the electrical discharge machining process that reduce machining efficiency. In the present study, a novel nitrogen (N2) gas–liquid mixed-based electrical discharge machining (EDM) technology was proposed to increase machining efficiency for machining of Inconel 718. A periodic bidirectional tool rotation was proposed in EDM for better circulation of dielectric fluid to the machining area. Experiments were conducted at three levels of current (4, 5, and 6 A), duty cycles (50%, 55%, and 60%), and gas pressures (0.015, 0.02, and 0.025 MPa), and the surface roughness, metal removal rate, and microhardness were compared with EDM without N2 gas. The periodic bidirectional rotation of the tool promoted the proper spreading of dielectric fluid along with the N2 gas, thereby the debris were expelled out from the electrode gap and the metal removal rate increased with reduced surface defects. The metal removal rate and microhardness were improved by 31% and 68%, respectively, and the surface roughness was reduced by 42%. The process parameters were optimized using the particle swarm optimization technique and optimum parameters were found to be 7.403 A of current, 45.407% of duty cycle, and 0.030 MPa of gas pressure. Surface defects like blow holes, micropores, and surface cracks were reduced in the EDM with N2 gas.