The Effect of SiC Powder-Mixed Dielectric Fluid on Electrical Discharge Machining Using the Taguchi Method

Patittar Nakwong; Apiwat Muttamara

doi:10.48084/etasr.18644

Authors

Patittar Nakwong Department of Applied Science, Faculty of Science and Technology, Phranakhon si Ayutthaya Rajabhat University, Ayutthaya, Thailand
Apiwat Muttamara Faculty of Engineering, Thammasat School of Engineering (TSE), Thammasat University, Khlong Luang, Phatumthani, Thailand

Volume: 16 | Issue: 3 | Pages: 37085-37092 | June 2026 | https://doi.org/10.48084/etasr.18644

Received: 10 March 2026 | Revised: 7 May 2026 | Accepted: 17 May 2026 | Online: 6 June 2026

Corresponding author: Apiwat Muttamara

Abstract

This study employs the Taguchi L9 orthogonal array to evaluate the effects of Silicon Carbide (SiC) powder addition (4 g/L, 6.3 µm particle size) in die-sinking Electrical Discharge Machining (EDM) of SKD11 tool steel by using a brass electrode. Three parameters were investigated at three levels: peak current (15–24 A), Duty Factor (DF) (60–80%), and electrode servo feed rate (120–180 mm/min). The results showed that SiC Powder-Mixed EDM (PMEDM) improved the Material Removal Rate (MRR) by approximately 9.51% and increased the regression model accuracy from an adjusted R² of 82.28% to 91.79% compared to conventional EDM. Surface microhardness increased from 720 HV to 850 HV, while white layer thickness increased from 8.5 μm to 12.3 μm. However, Surface Roughness (SR) (Ra) deteriorated under PMEDM conditions. DF was identified as the most influential parameter affecting both MRR and SR, whereas servo feed rate showed minimal influence. The study demonstrates that SiC-PMEDM enhances machining efficiency and surface hardening, but introduces a trade-off with surface quality, providing useful guidance for parameter optimization in rough machining applications of hardened tool steels.

Keywords:

Electrical Discharge Machining, Taguchi technique, SKD11 steel, Silicon Carbide powder, electrode, Powder-Mixed EDM (PMEDM), die-sinking EDM, white layer thickness

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