International Journal of Modern Engineering Research (IJMER) www.ijmer.com Vol.2, Issue.6, Nov-Dec. 2012 pp-4462-4464 ISSN: 2249-6645 www.ijmer.com 4462 | Page Harpreet Singh, 1 Amandeep Singh 2 1 Department of mechanical Engg YCOE Talwandi Sabbo 2 Department of mechanical Engg FCET Ferozepur ABSTRACT: Electric discharge machining is used for machining of hard materials. Tool material is of great importance because it affects material removal rate as well as surface finish of work piece. In this article we study the wear behavior AISI D3 Die steel in EDM and compare the tool wear rate of cryogenic treated cooper and brass electrode with simple copper and brass electrode on machining of AISI D3 die steel using current setting as 4A and 8A. The electrolyte is used kerosene oil. Keyword: Current, EDM, surface finish, Wear I. Introduction Technological advances have led to an increasing use of high strength, high hardness materials in manufacturing industries. In the machining of these materials, traditional manufacturing processes are being replaced by more advance techniques like electro discharge machining, electric chemical machining and laser machining. (Lee et al., 2003). In non-traditional processing electrical discharge machining (EDM) has tremendous potential on account of the versatility of its application and it is except to be successfully and commercial utilized in modern industries (Habib, 2009). Electrical discharge machining is highly developed technology which account about 7% of all machine tools sales in the world. (Leao et al., 2004). In EDM process the material removal is achieved by preferential erosion of work piece electrode as controlled discrete discharge are passed between the tool and the work piece in a dielectric medium (Wong et al., 1995). Electric discharge machining one of the most popular non-traditional material removals process and has became basic machining method for the manufacturing industries of areospace, automotive, nuclear and medical (Kiyak et al., 2007). In the EDM process there is no direct contact between electrode and the component during machining and therefore no deformation occurs even for thin components (Lee et al., 2003). In the EDM process to obtain the maximum material removal with minimum tool wear, the work material and tool must be set at positive and negative electrode (Che Haron et al., 2008). The EDM process is thermal energy based process in which the use of thermal energy to generate heat that melts and vaporized the work piece by the ionization within the dielectric medium. The source of energy used is amplified light, ionized material and high voltage. Examples are laser beam machining, ion beam machining, and plasma arc machining and electric discharge machining (Kiyak et al., 2007). This paper describe the wear behavior of AISI D3 Die steel in EDM and compare tool wear behavior of cryogenic treated cooper and brass electrode with simple cooper and brass electrode which Assist in choosing optimum electrode II. Experimental detail 2. 1 Work piece material AISI D3 die steel was used as work piece material. Sample of size 25mm×18mm×6mm were prepared by using wire EDM. The prepare sample were heat treated to improve their hardness. After heat treatment the hardness of work piece material was 58HRc. Table 2.1 shows the chemical composition of work piece material. Table 2.1 - The chemical composition of AISI D3 die steel C% Si% Mn% Cr% Cu% 1.88 0.5 0.38 11.5 0.16 2. 2 Tool Preparation The electrodes having the size of 16 mm diameter and 55 mm length were prepared out of the rods of Copper and Brass for performing the experiments. After preparing the required size the face of all the electrodes was polished so as to get good surface finish using different emery papers ranges from 220 to 2000 grit size following general metallographic procedure. After that half the number of the electrodes of Cu and Br were cryogenically treated to improve properties. Following Table 2.2 and 2.3 show the chemical composition of copper and brass electrode Table 2.2 - The chemical composition of the copper electrode Cu% Zn% Al% Bi% Pb% 99.8 0.057 0.15 0.0011 0.0008 Table 2.3 - The chemical composition of the brass electrode Cu% Zn% Pb% Sn% Fe% Ni% 58.8 37.2 2.7 0.5 0.9 0.16 2. 3 Dielectric used The commonly available kerosene oil is used as dielectric fluid for all the experiments. The properties of the kerosene oil are shown in the Table no. 2.4. Table 2.4 - Properties of kerosene oil Surface Tension N/M Density Kg / M³ Dynamic Viscosity 0.028 820 2400 2. 4. Machining process Machining was performed on the electronics CNC EDM machine Each experiment was performed for fix time period of 20 min using the input process parameters as current using four different types of electrodes i.e. Cu, cryogenic treated Cu, Br and cryogenic treated Br. The weight of the work pieces and electrodes was done before machining and after machining on the weighing machine with least count of 1 mg Wear Behavior of AISI D3 Die Steel Using Cryogenic Treated Copper and Brass Electrode in Electric Discharge Machining