Parameter optimization in the enhancement of MRR of titanium alloy using newer mixing method in PMEDM process

The addition of powders in electrical discharge machining (EDM) reduces the breakdown strength of the liquid dielectric, thereby enhancing the occurrence of early spark, and aids in machinability. Challenges occur in the sustainability of the powder mixed electrical discharge machining (PMEDM) process in terms of homogeneity of the powder-dielectric mixture and adverse effects of these powders on the impellor of the pump, maintaining the concentration of the powder–dielectric mixture for a wide range of powders at varied size. In this investigation, an attempt is made to address these challenges and limitations in performing PMEDM process by developing a newer mixing method for PMEDM. The Taguchi L18 orthogonal array has been selected to study the material removal rate (MRR) of titanium grade 5 alloy. Gap current, duty factor, pressure of the powder mixed dielectric fluid, type of powder, and concentration of the powders have been considered as the process variables. The results found to be satisfying with increase in MRR. The confirmation experiments indicate considerable increase in MRR. This newer system is capable of performing sustainable manufacturing method irrespective of the nature of the powder and the particle size of the additive powders, that are permissible in the inter-electrode gap as it restricts the size of the powder, added in the PMEDM process. © 2023, The Author(s).