Table 3.
Review on optimization of process parameters.
| Work Material | Powder | Input Parameter | Response Variables | Optimization Technique | Results | Reference |
|---|---|---|---|---|---|---|
| En-31 | Silicon | Peak current, Pulse on, Duty cycle, Powder concentration | MRR, SR | Response surface methodology (RSM) | Powder concentration and peak current were the most influential parameters | [70] |
| Inconel 718 | Aluminum | Voltage, Discharge current, Duty cycle, Powder concentration | MRR, SE, WR | One variable at a time | Size and particle concentration significantly affect machining efficiency | [81] |
| AISI-D2 Die steel |
Silicon | Peak current, Pulse on time, Pulse off time, Powder concentration, Grain, nozzle flushing | MR | Taguchi method | The peak current and concentration of silicon powder mostly influences the machining rate | [41] |
| EN-8 | Chromium | Current, Tool angle, Powder concentration, Duty cycle | MRR, TWR | RSM | The most significant parameters affecting MRR are powder concentration and current, whereas, current and electrode angle greatly influences TWR | [69] |
| EN-19 | Nickel micro powder | Peak current, Duty cycle, Electrode angle, Powder concentration | MRR, TWR | RSM | ANOVA results revealed that the current was the most dominant factor affecting both MRR and TWR increases with increase in current and powder concentration | [79] |
| AISI 1045 Steel |
Aluminum | Current, Voltage, Pulse on time, Duty factor constant | MRR, SR | Taguchi method | As the concentration of aluminum powder and grain size in EDM oil increases, surface roughness starts decreasing. MRR and surface roughness are equally important. With the increase in concentration of aluminum powder and grain size MRR and surface finish of AISI 1045 Steel increases | [63] |
| W300 Die Steel |
Aluminum | Peak current, Pulse on time, Powder concentration, and polarity | MRR, EWR, SR, WLT | Signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) | Polarity plays an important role in PMEDM. High MRR is obtained in positive polarity, whereas better surface quality (surface roughness and white layer thickness) is achieved in negative polarity. Distilled water can be used as dielectric fluid instead of hydrocarbon oil and, moreover, the performance can be improved by the addition of aluminum powder | [57] |
| EN 31 Steel | Silicon | Pulse on time, Duty cycle and Peak current, Powder material, Powder size, Powder concentration, Dielectric type, Peak voltage, Pulse off time, Polarity, Inter electrode gap (IEG) | MRR, TWR, WR, SR | RSM | MRR and SR roughness have been measured for each setting. The use of powder-mixed dielectric promotes the reduction of surface roughness and enhances material removal rate | [80] |
| SKD-11 | Aluminum chromium copper and silicon carbide powders concentration | Pulse on time, Peak current | MRR, TWR, SR | RSM | The discharge gap distance and material removal rate increased as powder granularity was increased. Aluminum produced the largest discharge gap enlargement and silicon carbide produced the smallest. | [82] |
| AISI D2 Die steel | Chromium | Peak current, Pulse on time, Pulse off time, Powder concentration | MRR, TWR, SR | Taguchi, Anova | With the increase in current and pulse-on time, MRR increases. Due to the increased concentration of chromium powder, MRR tends to decrease. TWR is mainly affected by current. With the increase in current, TWR increases. Also, TWR tends to decrease with the increase in chromium powder concentration. surface roughness is higher with the increase in pulse-off time | [83] |
| AISI D3 Die Steel | Aluminum Powder | Peak current, Pulse on time | MRR, TWR, SR | Central composite design (CCD) of response surface methodology (RSM) | Maximum MRR is obtained at a high peak current of 14 Amp, higher Ton of 150 μs, and high concentration of Al powder 6 g/L. Low TWR and SR are made with low peak current of 2 Amp, lower ton of 50 μs and higher concentration of Al powder of 6 g/L. | [84] |