Experimental Study of White Layer Thickness and Hardness Reduction in EDM Using Flux Powder

Abstract

In the mold manufacturing sector, the machining process utilizing Electrical Discharge Machining (EDM) is extremely significant. On the sliced surface, however, there is always a disserved white layer. The white layer has been thinned or softened in various ways in order to make it easier to remove. Powder Mix EDM (PM-EDM) is a technique that involves mixing powder with a dielectric fluid. Powder fluxes from welding electrodes comprising a variety of organic and inorganic components were used in this investigation.  Flux flakes are then crushed using a conventional blender. Refining the powder can be repeated until it reaches the desired grain diameter. The powder is selected with a maximum diameter of 40 µm, by sieving using a 400 mesh filter. With this filter a powder diameter \(\leq\) 37 \(\mu \mathrm{m}\) will be obtained. Then, it was tested using kerosene dielectric fluid mixed with the flux powder with concentrations of 0 g/l, 2g/l, 4g/l, 6g/l, 8g/l, 10g/l, and 20g/l. In addition, all machining parameters are constant with the expectation that the cutting result is only affected by flux concentration. White layer measurement results showed a decrease in thickness of 42% in the use of flux concentrations between 2% to 8%.