Enhancing Efficiency in Thermoelectric Removal Process: A Comprehensive Study on P/M-Made Al-Cu-ZrB2 Nano-Composite Electrodes on SS205 Alloy

The thermoelectric energy between the material and the cutting electrode is essential to the EDM process. This research assesses the new Nano electrodes and input settings for SS205 electric discharge machining (EDM). In order to remove the product electro thermally, parameters such as current, pulse on, and pulse off are taken into account during sequential, independent discharges between the EDM tool and the specimen while using EDM oil as a dielectric fluid. Together with the SS205 electrode work piece, the electrode, which is made of 90% aluminium reinforced with 5% copper and 5% zirconium di-boride, is used for testing. The P/M process is used to create it. To optimize, we use the full-factorial central composite design based on response surface methodology (RSM) to create the set of experiments (20 runs). Analysis of variance (ANOVA) then confirms the suitability of the suggested models. ANOVA determines which process factors significantly influence performance attributes. Die-sinker EDM using an Al-Cu-ZrB2 composite electrode shows promise for lowering production expenses and wear. SEM is used to analyze surface imperfections both before and after machining. Parameters such as Ton of 50μs, T off of 80μs, and SV of 12 amps provide a wear rate of 0.0008 g/min, which is minimal. At 0.0107 g/min, high removal rates are achieved with Ton of 70μs, T off of 90μs, and a SV of 12 amps. The settings for better surface roughness are being optimized further, with the best SR obtained at 2.91μm. Lastly, in order to assess the effectiveness of the chosen desirability technique, the optimized outcomes are verified against the experimental findings.