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COMPARATIVE ANALYSIS OF VARIOUS AA7075 COMPOSITE MEATL MATRIX MACHINING PARAMETERS AND GEOMETRICAL CHARACTERISTICS BY USING EDM PROCESS

AUTHORS:
V Sarayu
C Vijay Dharsan
M Thirunavukkrasu
S Vijay Baskar
Mentor
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This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Abstract

In the mechanical field, the trend of using lightweight, slim, and compact mechanical components in the medical, nuclear reactor, aerospace, and automotive industries leads to the growth of strong materials with high-temperature resistance properties and strength for various applications. These materials have various features, like being highly corrosion resistant, less heat sensitive, tougher, and harder, but it is also difficult to machine . The conventional methods are inefficient in machining these "difficult-to-machine" materials with higher accuracy. Additionally, materials with high surface finishes, tight tolerances, and complicated geometries make conventional methods difficult. It sparks the evolution of advanced and new technologies which compute with ease and precision. Electrical discharge machining (EDM) is widely applied to machines like high-strength and temperature-resistant (HSTR) alloys and 'difficult-to-machine.' It is mainly utilized in the mold and die-making industries. Joseph Priestly, a physicist, discovered the corrosive impact of electrical discharges on metals in 1770. Dr. Russian scientist B.R. Lazarenko and Dr. N.I. Lazarenko developed the later EDM method in 1943. Intermittent arcing in the air between electrodes attached to a DC power source was used to detect material erosion.


Electrical discharge machining (EDM) is a non-traditional thermoelectric machining method of removing materials by generating a sequence of electric sparks when electrodes are held closely together in a dielectric medium. A large potential difference is applied across them. These sparks cause localized zones of high temperature, which causes the material in the workpiece to melt and vaporize. The inter-electrode gap of the first spark is minimum.


The machine regions are overheating, resulting in minimum accuracy. Early power supplies of the resistance-capacitance (R-C) variety, commonly referred to as the Lazarenko, employed a circuit that served as a spark producer for EDM machines. The development of orbiting systems and the implementation of pulse and solid-state generators during the 1960s helped ease the problems associated with weak electrodes. Due to the advancement, the number of electrodes utilized to create cavities decreased in the 1970s. The first generation of computer numerical controlled (CNC) EDM was released in the United States of America in the 1980s, which greatly increased the productivity of EDM. CNC control system enables smoother finishing cut through the Self-regulated and un attended machining.

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Sarayu, V., Dharsan, C. V., Thirunavukkrasu, M. & Baskar, S. V. (2026). Comparative Analysis of Various Aa7075 Composite Meatl Matrix Machining Parameters and Geometrical Characteristics by using EDM Process. International Journal of Science, Strategic Management and Technology, 02(05). https://doi.org/10.55041/ijsmt.v2i5.361

Sarayu, V, et al.. "Comparative Analysis of Various Aa7075 Composite Meatl Matrix Machining Parameters and Geometrical Characteristics by using EDM Process." International Journal of Science, Strategic Management and Technology, vol. 02, no. 05, 2026, pp. . doi:https://doi.org/10.55041/ijsmt.v2i5.361.

Sarayu, V,C Dharsan,M Thirunavukkrasu, and S Baskar. "Comparative Analysis of Various Aa7075 Composite Meatl Matrix Machining Parameters and Geometrical Characteristics by using EDM Process." International Journal of Science, Strategic Management and Technology 02, no. 05 (2026). https://doi.org/https://doi.org/10.55041/ijsmt.v2i5.361.

References
[1] Muhammad Umar Farooq, 'Performance evaluation of surfactant mixed dielectric and process optimization for electrical discharge machining of titanium alloy Ti6Al4V', CIRP Journal of Manufacturing Science and Technology, vol. 43, pp. 42-56.

[2] V.P. Srinivasan, Experimental investigation on electrical discharge machining of ceramic composites (Si3N4-TiN) using RSM Int. J. Computational Materials Science and Surface Engineering, Vol. 7, No. 2, 2018

[3] Prabu Rajendran, Velmurugan Duraisamy Optimization on the electrical discharge machining (EDM) process parameters of aged AA7075/TiC metal matrix composites July-September 2023, 59 (3), e245 ISSN-L: 0034-8570 https://doi.org/10.3989/revmetalm.245.

[4] Farooq, MU & Anwar, S 2023, 'Investigations on the surface integrity of Ti6Al4V under modified dielectric (s)-based electric discharge    machining using cryogenically treated electrodes', Processes, vol. 11, no. 3, p. 877.

[5] Vidyapati Kumar, Abhishek Mohata, Application of SWARA-CoCoSo-based approach for tool selection of an electrical discharge machining process  Sustainable Production, Instrumentation and Engineering Sciences https://doi.org/10.57223/spies.2023.1.1.04.

[6] Equbal, A, Ahmad, S, Badruddin, IA, Khan, ZA, Kamangar, S & Javed,S 2023, 'Evaluating machining performance of acrylonitrile-butadienestyrene

(ABS) based electrical discharge machining (EDM) electrodes 128fabricated by fused deposition modelling (FDM) followed by a novel metallization method', Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, p. 09544054221151093.

[7] Kumar, S & Sen, D 2023, 'Effect of tool size and cavity depth on response characteristics during electric discharge machining: an experimental investigation', International Journal of Machining and Machinability of Materials, vol. 25, no. 1, pp. 1-20.

[8] Chinmaya P. Mohanty · Siba Sankar Mahapatra Manas Ranjan Singh A particle swarm approach for multi-objective optimization of electrical discharge machining process © Springer Science+Business Media New York 2014.

[9] Viet D. Bui, VD, Mwangi, JW & Schubert, A 2019, 'Powder mixed electrical discharge machining for antibacterial coating on titanium implant surfaces', Journal of Manufacturing Processes, vol. 44, pp. 261-270.

[10] Liu, Y.; Qu, J.; Zhao, K.; Zhang, X.; Zhang, S. Study of the High-Efficiency Ejecting-Explosion EDM of SiCp/Al Composite. Micromachines 2023, 14, 1315. https://doi.org/10.3390/ mi14071315.
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