A systematic review on powder mixed electrical discharge machining

Area of Science:

• Material Science
• Manufacturing Engineering
• Tribology

Background:

• Advanced materials possess excellent mechanical and thermal properties but are challenging to machine using conventional methods.
• Electrical Discharge Machining (EDM) is a non-contact thermo-electric process suitable for hard, complex-shaped materials, but suffers from poor surface finish and low material removal rates.

Purpose of the Study:

• To provide a comprehensive understanding of the Powder Mixed Electrical Discharge Machining (PMEDM) process.
• To review and analyze the effects of process parameters in PMEDM for performance enhancement.
• To guide researchers in achieving improved quality levels through PMEDM.

Main Methods:

• Review of existing literature on Electrical Discharge Machining (EDM).
• Analysis of the Powder Mixed Electrical Discharge Machining (PMEDM) technique, involving the addition of metallic powders to dielectric fluid.
• Study of how powder addition influences dielectric conductivity and spark gap characteristics.

Main Results:

• Metallic powder addition significantly enhances the dielectric fluid's conductive strength.
• Increased spark gap distance and improved volumetric material removal rates are observed in PMEDM.
• PMEDM offers potential for superior surface finish compared to conventional EDM.

Conclusions:

• PMEDM is a promising evolution of EDM, addressing limitations of the traditional process for advanced materials.
• Careful selection and control of process parameters are crucial for optimizing PMEDM performance.
• Further research into PMEDM is essential for its widespread industrial adoption and achieving higher manufacturing quality.