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In this research paper, drinking water was used as a dielectric fluid, and EDM parameters such as pulse on and off times, discharge current, and graphite powder concentration were used to machine Ti-6Al-4V. A graphite powder concentration of 4.5 grams per liter, 9 grams per liter, and 13.5 grams per liter was mixed in water. An orthogonal array based on Taguchi L15 was used to conduct the experiments. Processes of significance analyzing the variance (ANOVA) was done for each parameter. Additionally, micro hardness tests and EDAX analysis were also carried out. The purpose of this research was to increase the MRR and reduce the Ra and recast layer thickness (RLT). [ABSTRACT FROM AUTHOR]

The work-material deformation is very large and both the tool and workpiece temperatures are high in thermal drilling. Modeling is a necessary tool to understand the material flow, temperatures, stress, and strains, which are difficult to measure experimentally during thermal drilling. The numerical analysis of thermal drilling process of aluminum metal matrix composite has been done in the present work. In this analysis the heat flux of different stages is calculated. The calculated heat flux is applied on the surface of work piece and thermal distribution is predicted in different stages during the thermal drilling process. [ABSTRACT FROM AUTHOR]