Examinations concerning the electric discharge machining of AZ91/5B4CP composites utilizing distinctive electrode materials

Abstract

ABSTRACT In this study, investigation has been conducted in the focus of obtaining better surface finish in the electro discharge machining (EDM) of AZ91/5B4Cp magnesium composites using distinctive sort of anode viz. copper, tungsten–copper, brass, aluminum and 20Gr/AA6061 (GRAL-20) composites. The process parameters, pulse on time and current were performed to research the machining qualities through material removal rate (MRR) and tool wear rate (TWR). The machined composites were examined by optical microscopy (OM) and scanning electron microscopy (SEM). The formation of black spots was observed on machining with copper–tungsten and these black spots were not found when GRAL-20 was used as electrode. Machined with GRAL-20 electrode leads to the increase in spark gap, hence adequate flushing occurs; it eliminates re-melted layers on machined surface results in better surface roughness value. The results revealed that GRAL-20 electrodes posses better MRR followed by copper electrode whereas tungsten–copper exhibits better TWR followed by GRAL-20 electrode.