Development of tool electrode by powder metallurgy technique and analysis of tool wear rate by design of experiment methodology

In present work, a new hybrid metal matrix composite (MMC) using powder metallurgy (P/M) technique has fabricated and tested using an electric discharge machine (EDM) to reduce tool wear rate (TWR). MMC was developed using Cu as the matrix material, with W, Si, and Mn as reinforcement. The Taguchi approach was employed to build the experimental runs for this work, which was useful in determining the optimal (Cu–W–Si–Mn) MMC combination. For the current analysis, each element was separated into four levels. To conduct this study, the MMC material used as a tool electrode and kept the EDM machining parameters constant. The Cu matrix material is employed in 16 distinct experiments with varying Si, W, and Mn percentages. The fabricated electrode was used to machine a circular hole in heat-treated EN-24 strong steel. ANOVA proved very useful in determining if those regression models were suitable for the current investigation. The Taguchi and EDM experiments yielded critical data. The studies discovered that W is the most important factor in TWR regulation, but when Mn in the MMC electrode grows, TWR also increases, and Mn helps to increase the quantity of material removed from the object. To optimize the tool’s TWR by fabricating a metal matrix composite tool electrode with a greater W–Si–Mn ratio, it was discovered that 9% W, 9% Mn, and 6% Si were optimal.