Currently, powder mixed dielectric application in electro-discharge machining (EDM) is an emerging field to enhance process efficiency and achieve better surface quality along with surface modification. The current investigation utilizes two non-conductive powder mixed dielectrics i.e., urea mixed distilled water and silica mixed distilled water for feasibility analysis by machining Inconel 625 alloy in Maglev EDM. The study emphasizes on the effect of both the dielectrics on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) achieved during Maglev EDM operation. The investigation has been performed using a cylindrical brass tool at discharge voltage (26V) and discharge current (200mA) for both dielectrics. The voltage-current (V-I) waveform acquired during machining operation illustrates better stability and consistency in discharge. The surface topology of the processed workpiece have been inspected using 3D surface profiles and scanning electron microscopy (SEM) for both the dielectric conditions to analyze the presence of surface anomalies and debris particles. The elemental analysis of machined surface examines the surface alloying phenomena due to material migration effect. Maximum MRR (961.5 μg/min) and lower Ra (4.71 μm) were observed using urea mixed dielectric condition, and low TWR (144 μg/min) was achieved using silica powder mixed condition.

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