Performance and Wear Analysis of Al-Cu-ZrB2 Nano-Composite Electrodes in EDM Machining of D2 Die Steel

The goal of this research study is to enhance EDM machining performance by reducing electrode wear rate, improving surface roughness, and increasing the material removal rate. To overcome the drawbacks of Pure aluminum electrode Prepared a novel nanocomposite electrode for die-sinker EDM an aluminum base Nanocomposite material reinforced with 2.5% copper and 2.5% zirconium dibromide composite electrodes can lower wear and manufacturing costs. Unlike conventional studies focusing on standard copper or graphite electrodes, our research explores the performance of innovative Al-Cu-ZrB₂ Nano-composite electrodes. It is fabricated through powder metallurgy. The input parameters of the EDM process that affect how well the machining process performs are the discharge current, spark-on time, Pulse off time, workpiece material, tool material and inter-electrode distance. For machining analysis and optimization carried out using Analysis of Variation, the RSM technique of experimentation was selected. The workpiece chosen for EDM machining in this experimental study was D2 Die steel. To get a low wear rate, the following input variables must be used: The lowest wear rate obtained during the EDM machining was 0.0006 g/min, the optimal pulse ON is 50μs, the optimal pulse OFF is 80μs, and the current is 12 amps. The research highlights the attainment of lower surface roughness values (1.710μm) by utilizing specific EDM parameters: Ton set at 30μs, Toff at 100μs, and Current at 12A. Surface imperfections induced by different input factors are identified via the use of optical microscopic pictures.