Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

A review of the available literature on powder mixed electrical discharge machining (PMEDM) indicates that most research has been done for “die sinking mode” whereas “wire cut not received due attention despite being an important process variant. This work employs silicon carbide (SiC) dielectric fluid AISI D2 in cut” mode with re-circulating molybdenum wire (an economic and chemically stable proposition as a tool). The effect five parameters (powder concentration, peak current, pulse time, nozzle flushing pressure stand-off distance) evaluated surface roughness, kerf width, material removal rate, wear ratio using Taguchi’s approach followed by analysis variance (ANOVA) determining statistically significant factors at 95% confidence level. It is found higher current low to moderate concentration levels (2 4g/l) deteriorate quality; values distance are also seen adversely affect it. For time well its interactions significant. smaller concentrations (2g/l reduces MRR. ratio, sole factor (PCR ~65%). SEM machined workpiece maximum MRR condition quantifies recast layer ~19microns. An indirect comparison reported non-powdered EDM similar (molybdenum), use SiC maintains roughness values, much harder used this work.