An Analysis of Machining Response Parameters, Crystalline Structures, and Surface Topography During EDM of Die-Steel Using EDM Oil and Liquid-Based Viscous Dielectrics: A Comparative Analysis of Machining Performance

In this work, a highly carbonated liquid has been utilized as a dielectric medium in the EDM process. The effect of the dielectric medium has been investigated and then, finally, compared with EDM oil. The outcomes have demonstrated that discharge energy density has escalated to fierce-extent, thus, removing a voluminous amount of material from the workpiece. The results also emphasize that the dielectric medium has a viscosity (8.6 CS) higher than EDM oil (2.16 CS) is helpful for higher MRR. The debris particle has remained suspended in the dielectric medium due to its highly viscous properties leading to high MRR without any flushing technique. The process parameters, pulse-on-time, and peak current have dramatically influenced the EDM process. Further, the surface morphology has also been investigated. Results have also revealed that at a low peak current value, the MRR has increased by 155.55%, whereas, at a low value of pulse-on-time, MRR has decreased by 28.25%. At a high peak current value, MRR has increased by 217.55%, whereas, at a high value of pulse-on-time, MRR has increased by 324.05%. The highly carbonated liquid dielectric has considered the most suitable dielectric medium for high discharge energy. Micro-crack density and size have increased with MRR because of highly concentrated discharge energy. The recast layer thickness has increased with the dielectric medium's viscosity because of improper molten metal flushing, and the molten metal re-solidifies on the same surface.