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Analysis of Fatigue and Microhardness in Metallic Powder Mixed EDM

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Document pages: 12 pages

Abstract: The objective of this work research is to investigate the potential ofusing metallic powder mixed with electrical discharge machining (EDM)dielectric when machining hard electrically conductive materials. Nowadays, thedevelopment of industries requires hard materials for various applications.Machining the hard materials using the traditional processes lead to tool breakand poor machined product. Even when the conventional EDM can machine hard material as long as it is electrically conductive materials,the machined parts still present drawbacks. Metallic powder mixed with EDMdielectric (PMEDM) was hypothesized to improve the machined part. The presenceof metallic powder ensures uniform distribution of spark and the electricaldensity of the spark decreases which reduces craters, cracks and voids onmachined surface. The transfer and deposit of alloying elements during powdermixed electrical discharge machining improve the machined surface propertiesparticularly micro-hardness and fatigue. Discharge current (IP), gap voltage(GapV), ON-time (ON) and aluminum powder are selected as machined variableparameters and the output responses are fatigue performance, micro-hardness andsurface topography. The workpiece material selected is molybdenum high speed steel. Micro-hardness wasdetermined using micro-hardness tester device. The fatigue performance wasdetermined using empirical equation. Analysis of material transfer was doneusing energy dispersive spectroscopy (EDS) attached to FESEM. EDS analysisinvolves the generation of an X-ray spectrum from the entire scan area of theSEM. The use of PMEDM improved thefatigue, the micro-harness and the machined surface morphology as theabove-mentioned parameters increased.

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