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<p>One of the non-traditional techniques for processing hard and electrically conductive materials is the powder-mixed electric discharge machining, which involves no physical connection between the tool and work surface. Nimonic C-263, a nickel-based superalloy, is widely used in aerospace and automobile sectors due to its improved inherent properties such as high hardness at elevated temperatures, high creep and corrosion resistance and excellent intermediate temperature tensile ductility. This study investigates aluminium powder-mixed electric discharge machining of Nimonic C-263 while using non-toxic environment friendly dielectric, deionized water. The effects of altering parameters such as peak current (<i>I</i><sub>pc</sub>), pulse-on-time (<i>T</i><sub>on</sub>), pulse-off-time (<i>T</i><sub>off</sub>) and powder concentration (C) on material removal rate (MRR), tool wear rate (TWR) and average surface roughness (<i>R</i><sub>a</sub>) have been critically analysed. The observations show a rise in MRR with the increase in <i>I</i><sub>pc</sub>, <i>T</i><sub>on</sub> and C. <i>R</i><sub>a</sub> is found to increase with an elevation in <i>I</i><sub>pc</sub> and <i>T</i><sub>on</sub> while it declines with a rise in C. Process parameter optimization through grey relational analysis reveals the best parametric combination as <i>I</i><sub>pc</sub> = 8 A, <i>T</i><sub>on</sub> = 1 µs, <i>T</i><sub>off</sub> = 5 µs and C = 9 kg m<sup>−3</sup>. SEM analyses depict that the surface quality deteriorates at higher values of <i>I</i><sub>pc</sub>.</p>

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Electric discharge machining parameter optimization for Nimonic C-263 using aluminium powder-infused green dielectric

  • 期刊论文

  • 发表日期：

    2025年6月27日

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  • PRASAN RALPH DEWAN,
  • PRANAB KUMAR KUNDU

摘要

One of the non-traditional techniques for processing hard and electrically conductive materials is the powder-mixed electric discharge machining, which involves no physical connection between the tool and work surface. Nimonic C-263, a nickel-based superalloy, is widely used in aerospace and automobile sectors due to its improved inherent properties such as high hardness at elevated temperatures, high creep and corrosion resistance and excellent intermediate temperature tensile ductility. This study investigates aluminium powder-mixed electric discharge machining of Nimonic C-263 while using non-toxic environment friendly dielectric, deionized water. The effects of altering parameters such as peak current (Ipc), pulse-on-time (Ton), pulse-off-time (Toff) and powder concentration (C) on material removal rate (MRR), tool wear rate (TWR) and average surface roughness (Ra) have been critically analysed. The observations show a rise in MRR with the increase in Ipc, Ton and C. Ra is found to increase with an elevation in Ipc and Ton while it declines with a rise in C. Process parameter optimization through grey relational analysis reveals the best parametric combination as Ipc = 8 A, Ton = 1 µs, Toff = 5 µs and C = 9 kg m−3. SEM analyses depict that the surface quality deteriorates at higher values of Ipc.