EDM PROCESS OPTIMIZATION USING GRAPHENE-BASED NANOFLUIDS: SURFACE, MICROSTRUCTURAL, AND PERFORMANCE EVALUATION OF ALUMINUM 7075

Abstract

The given research is devoted to measuring the surface conditions and machining quality of the aerospace-grade alloys machined with the help of Electrical Discharge Machining (EDM) in a dielectric medium supplemented with graphene. EDM is an unconventional, popular machining technique, which is particularly appropriate in machining intricate-to-machine titanium or nickel-based super-alloys, which are common in the aerospace sector. The introduction of graphene nanoparticles into the dielectric fluid will enhance efficiency in machining as the thermal and electrical conductivity of the medium will be changed [1].

The objective of the work is the influence on the main output variables of graphene concentration on such parameters as the surface roughness, micro-hardness, recast layer development, and the alteration of the microstructure in the machined zone. In addition, the influence on the process performance indicators, including the tool wear rate (TWR) and material removal rate (MRR), is addressed adequately. The test results show that in the event that dielectric is mixed with graphene, it considerably improves the surface quality and MRR, and reduces micro-cracks and erosion of tools when compared to plain conversions which are registered using conventional EDM methods [1]. The obtained results are then used to conclude that graphene-aided EDM may be a practical way of improving the machinability and surface finish of aerospace alloys and consequently, development of more efficient, accurate and reliable components employed to the aerospace industry will be achieved [1].