Effects of powder additives suspended in dielectric on crater characteristics for micro electrical discharge machining

The effects of using powder additives suspended in dielectric on crater characteristics for micro electrical discharge machining (PSD micro-EDM) are investigated through the conduct of single RC discharge experiments at low discharge energies of 2.5 µJ, 5 µJ and 25 µJ. Through the introduction of additive particles into the dielectric, results of the single discharge experiments show the formation of craters with smaller diameters and depths, and having more consistent circular shapes than those produced in dielectric without additive. These craters also possess a noticeable morphological difference compared to those generated in dielectric without additive. In addition, discharge current measurements show a smaller amount of charges flowing between the tool electrode and workpiece, and at a slower flow rate when additives are present in the dielectric. Furthermore, based on the experimental results and findings from studies done in nanofluids, a hypothesis is made on the effects of powder suspended dielectric on the crater formation mechanism. The increased viscosity and enhanced thermal conductivity of a powder suspended dielectric lower the plasma heat flux into the electrode and raise the rate of heat dissipation away from the molten cavity. As a result, a smaller-sized crater having a larger amount of resolidified material within the crater cavity is formed.