A Comparative Investigation on Powder Mixed EDM Machining of Steel Alloys with Multi-Objective Optimization Using Fuzzy-TOPSIS Method

Md Nadeem Alam; Mohd Atif Wahid; Raghib Ahsan; Naveen Kumar; Shoaib Sabri

doi:10.24237/djes.2024.17402

Authors

Md Nadeem Alam
mdnadeemalam7@gmail.com
Department of Mechanical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia (A Central University), New Delhi (110025), India.
Mohd Atif Wahid School of Engineering & Technology, Vivekananda Institute of Professional Studies – Technical Campus, Delhi (110034), India.
Raghib Ahsan School of Engineering and Technology, SHARDA UNIVERSITY, Greater Noida, Uttar Pradesh (201306), India.
Naveen Kumar School of Engineering and Technology, SHARDA UNIVERSITY, Greater Noida, Uttar Pradesh (201306), India.
Shoaib Sabri Department of Mechanical Engineering, VCTM, AKTU Lucknow, Uttar Pradesh (226031), India.

Keywords:

PMEDM Process, Surface roughness, MRR, TWR, Fuzzy TOPSIS method, surface cracks, white layer, recast layer

Abstract

The current work offers a comparative study that examined the effects of various process parameters, such as dielectric fluid, current (IP), pulse on time (TON), and different conductive powder particles mixed dielectric fluids, on electrical discharge machining (EDM) of AISI 1040, EN31, and HCHCr steels, respectively. The findings indicate that adding conductive particles to the dielectric medium during the powder-mixed EDM (PMEDM) process enhances energy distribution across the spark gap, thereby improving material removal capacity and the surface characteristics of the machined surfaces. Experimental results show that the concentration of powder particles has the most significant impact on surface roughness (Ra) and tool wear rate (TWR), while the most critical factor affecting the material removal rate (MRR) is the current (IP). Additionally, increasing the IP and TON leads to the formation of continuous, thick cracks and a thin white coating on the EDMed surface, as evidenced by scanning electron microscopy (SEM) images of the surface morphology. The study also employs a multi-optimization technique using the Fuzzy-based TOPSIS method to investigate the cumulative effects of the control parameters on performance indicators, namely Ra, MRR, and TWR. In experimental run 8 i.e. moderate IP (5 A), higher TON (180 µs), and higher concentration of copper powder (10 g/l) mixed in EDM oil while machining of AISI 1040, the optimal results i.e. Ra is 5.983 µm, MRR is 27.243 mm3/min, and TWR is 0.775 mm3/min were obtained, respectively.

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Author Biographies

Raghib Ahsan, School of Engineering and Technology, SHARDA UNIVERSITY, Greater Noida, Uttar Pradesh (201306), India.

M.Tech. Scholar in the School of Engineering and Technology (Department of Mechanical Engineering)

Shoaib Sabri, Department of Mechanical Engineering, VCTM, AKTU Lucknow, Uttar Pradesh (226031), India.

Assistant Professor in the Department of Mechanical Engineering

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