Assessment of Surface Quality during EDM of AISI 4147 with Copper Tool

Durgesh Verma; Bhanu Pratap Singh; Ajay Kumar; Syed Asghar Husain Rizvi

doi:10.52756/ijerr.2024.v38.016

Durgesh Verma Department of Mechanical Engineering, Maharishi University of Information Technology, Lucknow-226013, India https://orcid.org/0009-0002-8766-2252
Bhanu Pratap Singh Department of Mechanical Engineering, Maharishi University of Information Technology, Lucknow-226013, India https://orcid.org/0000-0002-1757-9763
Ajay Kumar Department of Mechanical Engineering, Inderprasth Engineering College, Sahibabad, Ghaziabad-201010, India https://orcid.org/0000-0002-2787-7975
Syed Asghar Husain Rizvi Department of Mechanical Engineering, Khwaja Moinuddin Chishti Language University, Lucknow-226013, India https://orcid.org/0000-0001-7871-7907

DOI: https://doi.org/10.52756/ijerr.2024.v38.016

Keywords: AISI 4147, EDM, surface roughness, WLI

Abstract

This experimental assessment is performed to estimate the impact of EDM parameters on surface quality while machining AISI 4147 with a copper tool. The need of the present-day is to achieve good surface quality. Here, an investigation was performed to depict surface quality characteristics with respect to machine variables. The machined specimens were examined under white light interferometry (WLI) for the crests and troughs developed post-machining. The range of average surface finish was found to be between 5.32 to 7.67 µm. The test of model highlighted that the relation linking the EDM variables and surface roughness could be modelled using quadratic equations. As per the SMSS and lack of fit tests, a quadratic model is suggested for the roughness trend obtained. The analysis apprised that duration (p-value = 0.0006) major influence on the surface quality produced while the depth of machining (p-value = 0.9251). At all levels of on time, the surface roughness initially increases and then tends to decrease on increasing peak current. At all current levels, the surface roughness is almost constant with the machining depth; as suggested by ANOVA, it is the least influencing factor. At all levels of duration, the surface roughness is almost constant with depth of machining, and as suggested by ANOVA, it is the least influential factor. Model surface plots are curved representing the presence of quadratic terms in the model. Model validation for surface finish showed that the residual error was lower than 1.48%, proving the adequacy of the model.

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