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Effect of adding nano graphite powder on the material removal rate and
surface roughness of electric spark machining

Conference Paper · March 2024

DOI: 10.1063/5.0181547

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RESEARCH ARTICLE | FEBRUARY 10 2024

Effect of adding nano graphite powder on the material

removal rate and surface roughness of electric spark
machining 
Raed R. Shwaish  ; Shukry H. Aghdeab; Asaad A. Abbas

AIP Conf. Proc. 2885, 090002 (2024)

https://doi.org/10.1063/5.0181547

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14 May 2024 20:20:28

 Effect of Adding Nano Graphite Powder on The Material
Removal Rate and Surface Roughness of Electric Spark
Machining
Raed R. Shwaish1,a), Shukry H. Aghdeab1,b) and Asaad A. Abbas1,c)
1
Production Engineering and Metallurgy Department, University of Technology, Baghdad, Iraq

a)Corresponding Author: raed.r.shwaish@uotechnology.edu.iq

b)
Shukry.H.Aghdeab@uotechnology.edu.iq
c)
asaad.a.abbas@uotechnology.edu.iq

Abstract. Electrical Discharge Machining (EDM) is widely utilized to fabricate different conductive
materials counting those that are difficult to be machined with intricate profiles. Powder Mixed
Electro-Discharge Machining (PMEDM) could be a later advancement to upgrade the capabilities of
conventional EDM. In this operation, appropriate materials in Nano- powder shape are mixed within
the dielectric fluid. An equal percentage of Nano-graphite powder have been mixed with the
transformer oil and used as the dielectric media in this work. The aim of this study is to analysis the
outcome of some process factors such as nano-powder concentration, current, pulse on time, and pulse
off time of machining High-speed steel on the material removal rate (MRR), and surface roughness
(Ra). It is found that added nano-graphite mixing powder to the dielectric fluid enhanced the MRR
and Ra at various conditions. Maximum MRR was (38.784 mm 3/min) obtained at nano-powder
concentration of (10 g/l), current (30 A), pulse on time (70 µs), and pulse off time (55 µs), and better

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Ra was (3.612 µm) at (10 g/l, 10 A, 50 µs, and 55 µs). Results indicated that the proposed method
exhibited a material removal rate and surface finish 3.013, 1.729 times higher than that of without
adding nano-powder. The proposed method showed an increase in MRR by 66.81% and surface
roughness is improved by 42.18%.

Keywords- Electrical Discharge Machining, Nano-Powder Mixed Electro-Discharge Machining,

Material removal rate, Surface roughness.

INTRODUCTION

Electrical discharge machining (EDM) is widely used among nontraditional machining used for
processing tool mold, medical devices, injector nozzles and die industries. The ability to machine materials
regardless of their hardness and the ability to generate geometrically complex shapes increased the number of
applications for this process. [1]. The technique of introducing Nanopowder into EDM fluid called the powder
or Nanopowder mixed EDM (PMEDM) is introduced to keep the machining specifications and overcome the
part drawbacks. Despite of the wide improvements gained by PMEDM, the importance of the effect of
introducing powder in fluid in PMEDM processes on surface quality, part precise and machining time still needs
improvement and investigation. Introducing of powders in the fluid in PMEDM together with high ratios of
powder in the dielectric fluid was noticed as an excellent way to maximize surface finish and minimize
machining time. The powder electrical conductivity leads to maximizing the overall fluid conductivity, then
minimizing the strength of the dielectric of the fluid and enlarging the gap distance between the tool and the
machined surface. Maximizing the gap together with the high concentricity of particles in the dielectric improves
the discharging process to be more accurate and minimizes the need to back off the tool because of arcing and
short-circuiting, which gives minimum machining time [2]. Among these methods, powder mixed EDM is one
of the effective techniques for promoting the capabilities of conventional EDM by improving the material
removal rate and surface roughness as both of these responses are mainly considered by the industries [3]. In
PMEDM, appropriate materials in the form of tiny powders, such as graphite, iron, titanium, aluminum, silicon,

2nd International Conference on Renewable Energy (ICRE2022)

AIP Conf. Proc. 2885, 090002-1–090002-6; https://doi.org/10.1063/5.0181547
Published by AIP Publishing. 978-0-7354-4797-4/$30.00
090002-1
chromium, copper, or alumina, are mixed with the dielectric fluid, reducing the dielectric's dielectric ability and
widening the spark gap between the electrodes, allowing the electric discharge to distributed uniformly in all
directions. and as a result, MRR and surface quality improve. [4-6].

Extensive studies concerning the PMEDM and its optimization are available. Some of the most relevant
are listed as a continuation. A. Erden and S. Bilgin (1980) [7] were the first to introduce the concept of Powder-
mixed EDM (PMEDM), it has been studied the influence of carbon, aluminum, copper, and iron powders
mixed in dielectric fluid and conducted improved machining rates and reduced time-lags when the concentration
of powders increased in the gap space also reduced insulation strength of dielectric. K. Y. Kung et al. (2009) [8]
lead a study in the final stages of a low-level peak current below 3 A. Authors investigated the effect of the
concentration of aluminum powder particle, peak current, pulse on time and grain size on MRR and EWR
(electrode wear rate) through the powder-mixed EDM of cobalt-bonded tungsten carbide (WC–Co). S. Sharma
et al. (2010) [9] investigated the influence of aluminum powder concentration and grain size with reverse polarity
on EDM machining performance, such as material removal rate, tool wear rate, and surface roughness. It is
concluded experimentally, that with increasing concentration and changing the size of the powder grain, the
surface roughness and percentage wear rate decrease continuously, on the other hand, the material removal rate
and the tool wear rate increase. S. Assar Zadeh and M. Ghoreishi (2013) [10] effected on Aluminum oxide
(Al2O3) powder mixed electro-discharge machining using heat-treated die steel workpiece and tool electrode of
copper. Three of main input parameters (discharge current, pulse-on time, and voltage) were discussed on MRR
and Ra. The results are sets of optimum points that keep the Ra and all machining parameters in their specified
ranges and make the MRR as high as possible simultaneously. M. G. Rathi and D. V.Mane (2014) [11] The
impact of powder mixed EDM on Inconel 718 was discussed. Current, pulse on time, duty cycles, and mixed
powder (Sic, Al2O3, C) were the machining parameters used. With a current (Ip) of 18 A, a Pon of 5 µs, a duty
cycle of 85%, and graphite as the powder medium, the highest MRR is achieved. With an Ip of 12 A, a Pon of
20µs, a duty cycle of 90%, and Sic as the powder medium, a low TWR is obtained. Kolli and A. Kumar (2015)
[12] focused on optimizing the process parameters such as discharge current, powder and surfactant
concentration mixed in the dielectric when machining Ti-6Al-4V using Taguchi method. It was concluded that
mixing graphite powder and surfactant with dielectric fluid can improve MRR while lowering EWR, Ra, and
RLT under varied circumstances. S. Mohanty et al. (2018) [13] Conducted a study of the use of Al 2O3 Nano-

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powders in EDM process, a copper electrode with 12mm diameter was chosen to machining (AlSiCP12%) metal
matrix composite. Pulse on time (30, 60, 90) μs, pulse off time (10, 15, 30) μs, low current (6, 12, 18) A, high
current (1, 1.5, 2) A, and flushing pressure (0.2, 0.4, 0.6) kg/m 2. B. Surekha et al. (2019) [14] The effect of
aluminum has been analyzed, PMEDM input parameters namely peak current (6, 8, 10) A, gap voltage (40, 50,
60) V, pulse-on-time (50, 75, 100) μs, and concentration of powder (2, 4, 6) g/l on the MRR and TWR of
machining EN-19 alloy steel by using a yellow alloy of copper and zinc as electrode. Surface response modeling
adopted central composite designed to conduct experiments and create nonlinear models representing MRR and
TWR. They concluded when the input parameters changed from their lower-level to higher-level, the TWR value
had been raised by more than 50% which is not desirable. Maximum MRR was (0.0266 g/min) reached at (IP=10
A, CP=6 g/l, V=60 V, and Ton=100 μs) and Minimum TWR was (0.0079 g/min) attained at (IP=6 A, CP=6 g/l,
V=60 V, and Ton=50 μs). This paper attempted to study the effect of added nano-powder mixture of graphite
with different concentrations (0, 5, 10) g/l to transformer oil. Material removal rate, and surface roughness are
selected as response parameters to measure the EDM and NPMEDM process performance.

EXPERIMENTAL WORK
As indicated in Fig. 1, an experimental examination was carried out on a CHEMER EDM machine
(CM323C) housed in the University of Technology's Machine Tool Lab. The workpiece utilized in the experiment
was stainless steel 304, ASTM A 240, with dimensions of (40 x 30 x 1.7 mm). Table 1 summarizes the chemical
composition percentages of 304 stainless steel workpiece materials examined at the Central Organization for
Standardization and Quality Control / Ministry of Planning / Iraq and according to the ASTM E415 standard.
Table 2 presents many mechanical and physical characteristics of the workpiece. The electrode is composed of
99.74 % pure copper and has a 5-mm diameter. A nano-powder mix of graphite was added to the dielectric
solution, which was a type of transformer oil.

090002-2
 FIGURE 1. Model of the EDM machine (CM 323C).

TABLE 1. stainless steel 304 Chemical composition of workpiece.

Material Weight (%)
C 0.055
Si 0.58
Mn 1.08
P 0.03
S 0.02
V 0.142
Cr 19.4
Mo 0.24
Ni 8.95
Fe Balance

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TABLE 2. Mechanical and physical properties of the workpiece.
Hardness (kgf /mm2) 170
Elongation (precent in 50 mm) 60
Tensile strength (Mpa) 621
Density (g/cm3) 8.03
Melting point (0C) 1400-1450

Experiments were achieved in new tank that loaded with the nano-powder mixture of graphite beside
the transformer oil. A small pump was placed inside the tank to isolate the internally mixed nano powder to
avoid powder deposition at the tank bottom or insulating surface build-up. The viscosity of the transformer oil
dielectric was (28.01 Pa.s) tested at 23oC in the department laboratories and the particle size of both nano-
powders graphite (Gr) was (80 nm) which examined at the University of Technology , Nanotechnology and
Advanced Materials Research Center. The weight of workpiece and electrode are measured before and after
machining using an electronic weighing scale with accuracy of (0.0001g). The surface roughness for each
workpiece were measured after NPMEDM machining by using the portable surface roughness tester with an
accuracy of (± 0.05) µm. Fig. 2 shows the principle of nano-powder-mixed EDM.

FIGURE 2. Principle of nano-powder-mixed EDM.

090002-3
 The machining parameters included variable nano-powder concentration (nano-powders graphite),
current, pulse on time, and pulse off time. The range of the nano-powders graphite concentration was 0, 5, and
10 g/l, discharge current of 10, 20 and 30 amperes were used, in addition, pulse on time were selected as 50,
60 and 70 μs and pulse off time was selected as 35, 45 and 55 μs. According to the manufacturer's
recommendations, the remainder of the electric impulse parameters were kept constant (open gap voltage 140V
and negative tool electrode polarity). The aim of this study is to investigate the influence of nano-powder-mixed
dielectric on the MRR, and Ra via selecting various input machining parameters.

Table 3 shows the four parameters used in this study, each with three levels. furthermore, Table 4 shows
the input machining settings that haven't changed, moreover, Table 5 shows the experimental layout and response
result.

TABLE 3. Machining Parameters and their Levels.

Parameters Units Levels
1 2 3
Nano-Powder Concentration g/l 0 5 10
Current (IP) Amp 10 20 30
Pulse-on time (Ton) µsec 50 60 70
Pulse-off time (Toff) µsec 35 45 55

TABLE 4. unchanged input parameters.

Workpiece polarity Positive
Electrode polarity Negative
Dielectric fluid Transformer oil with Mixture nano-powder of Gr
High voltage 140 V 1.2 A
Pulse-off time 25 µsec
Servo feed 75 %

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Working time 5.0 sec
Jumping time 2.0 mm
Gap code 10
Depth of cut 1 mm

RESULTS AND DISCUSSION

Table 5 shows the experimental and predicted residual stress results based on machine parameter.
Minilab17 software was used to design the trials, which employed full factorial design to provide (all prospects)
27 number of experiments.

TABLE 5. Experimental, predict value and machine parameter.

Exp Nano-powder Current Pulse on Pulse off MRR Ra Pred Pred
NO. concentration (g/l) (A) Time(μs) Time(μs) (mm3/min) (µm) MRR SR
1 0 10 50 35 12.871 4.875 11.6624 4.74989
2 5 10 50 45 17.582 4.267 17.2591 4.40756
3 10 10 50 55 23.956 3.612 22.3511 3.68889
4 0 10 60 35 18.154 5.239 20.5674 5.03144
5 5 10 60 45 23.574 4.489 22.8911 4.68911
6 10 10 60 55 25.326 4.112 23.3687 3.97044
7 0 10 70 35 21.354 4.689 22.0041 4.94067
8 5 10 70 45 23.872 5.031 24.9004 4.59833
9 10 10 70 55 25.017 3.642 26.7017 3.87967
10 0 20 50 35 17.641 5.476 18.1691 5.51500
11 5 20 50 45 24.958 5.373 23.7657 5.17267
12 10 20 50 55 28.352 4.323 28.8577 4.45400
13 0 20 60 35 24.123 5.846 27.0741 5.79656
14 5 20 60 45 27.863 5.417 29.3977 5.45422
15 10 20 60 55 31.752 4.826 29.8754 4.73556
16 0 20 70 35 28.642 5.967 28.5107 5.70578
17 5 20 70 45 32.125 5.127 31.4071 5.36344
090002-4
 18 10 20 70 55 34.810 4.487 33.2084 4.64478
19 0 30 50 35 22.981 5.947 23.6615 6.01978
20 5 30 50 45 27.743 5.625 29.2582 5.67744
21 10 30 50 55 33.251 5.146 34.3502 4.95878
22 0 30 60 35 27.931 5.985 32.5665 6.30133
23 5 30 60 45 35.742 5.836 34.8902 5.95900
24 10 30 60 55 31.534 5.428 35.3679 5.24033
25 0 30 70 35 34.522 6.247 34.0032 6.21056
26 5 30 70 45 37.210 6.025 36.8995 5.86822
27 10 30 70 55 38.784 5.146 38.7009 5.14956

Nano-powder concentration is increasing with increase in MRR, and with increasing both current from
10, 20 and 30 A, pulse-on time 50, 60 and 70 μs and pulse-off time 35, 45 and 55 μs this occurred because
increasing in spark energy between the workpiece and electrode as a result of the high temperature on the
workpiece, an increase in temperature leads to an increase in MRR. Also, the greatest amount of Toff gives the
highest MRR since it increases the re-solidification period in the presence of a dielectric medium, resulting in
larger surface grains and therefore a greater MRR. Nan-powder concentration, current, Ton, and Toff have an
influence on MRR as shown in Fig.3.

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FIGURE 3. The effect of Nano-powder concentration, current, pulse on time (Ton) and pulse off time (Toff) on MRR.

Nano-powder concentration is increasing with improved surface finish (Ra) of the workpiece, and with increasing
both current from 10, 20 and 30 A, pulse on time 50, 60 and 70 μs and decrease pulse off time 35, 45 and 55 μs.
The effect Nano-powder concentration, current, Ton and Toff on Ra shown in Fig. 4

FIGURE 4. The effect of Nano-powder concentration, current, pulse on time (Ton) and pulse off time (Toff) on Ra.

090002-5
 CONCLUSIONS

The present study discussed about the effect of electrical process parameters (Nano-powder concentration,
Ip, Ton and Toff) on MRR and Ra for High-speed steel, once pure copper is used as a tool electrode. The following
conclusions can be noted:

• When the proportion of Nano-powder added to the solution (transformer oil) increases, the rate of the material
removed increases.
• Increasing the concentration of the added Nano-powder leads to improved surface finish of the workpiece and
this leads to better surface smoothness.

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