Effect of TiC Reinforcement in the Copper Tool on Roundness During EDM Process

In the present work, a copper (Cu) tool, reinforced with titanium carbide (TiC) particles, synthesized using powder metallurgy, is used to machine EN31 die steel using EDM machining. Various parameters were selected as process parameters to study tool shape as response. RSM was used to design the experiments and 52 experiments performed. The shape of tool was studied in terms of roundness of tool. Change in roundness of tool was analysed by analysis of variance and regression. Results revealed current and pulse on/off most significant parameters. Roundness value rose with increase in discharge current. On the other hand, it fell with rise in time of pulse on/off. Profile of tool and shape of tool were investigated by scanning electron microscopy (SEM). Comparison of Cu-TiC with Cu tooltip was performed to understand the effect cermet tooltip. The comparison of results showed that Cu–TiC tool was reduced out of roundness by 25%.