Effects of EDM Parameters on Surface Roughness and Electrode Wear Rate When Processing SKD11 Tool Steel

This research work describes the effect of powder concentration in dielectric fluid during electrical discharge machining (EDM) of mild steel on material removal rate (MRR), electrode wear rate (EWR) and work surface roughness (Ra). The machining parameters studied in this research are current (4.5A, 5.5A, and 6.5A) and concentration of the powder (30g/l, 60g/l, and 90g/l). It was decided to use copper (Cu) as the electrode, mild steel as the work material and tantalum carbide (TaC) as the powder to be mixed with the dielectric. Design-Expert software was used to design and analyze the experiments. The performance of machining was analyzed and it was found that powder concentration does not have much effect on MRR or work surface roughness (Ra). At low current powder concentration reduces electrode wear rate (EWR), but at higher current the situation is opposite. It was also found that in all conditions, MRR and EWR increases with increase in current. A higher current produces stronger spark with higher energy that melts more materials from the workpiece and the electrode. As a result both MRR and EWR increases and job surface becomes poor.

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Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

International Journal of Manufacturing Engineering ◽

10.1155/2014/259129 ◽

2014 ◽

Vol 2014 ◽

pp. 1-16 ◽

Cited By ~ 12

Author(s):

Teepu Sultan ◽

Anish Kumar ◽

Rahul Dev Gupta

Keyword(s):

Surface Roughness ◽

Response Surface Methodology ◽

Wear Rate ◽

Response Surface ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Electrode Wear ◽

Electrode Wear Rate ◽

Pulse On Time

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

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Effects of Pulse Duration and Current on EDM Process of Allegheny Ludlum D2 Tool Steel

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.315.369 ◽

2013 ◽

Vol 315 ◽

pp. 369-373

Author(s):

S. Sulaiman ◽

A.A. Khan ◽

M.A. Razak ◽

M.R. Ibrahim ◽

M.S. Yusof

Keyword(s):

Surface Roughness ◽

Wear Rate ◽

Pulse Duration ◽

Tool Steel ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Electrode Wear ◽

Machining Parameters ◽

Edm Process

The purpose of this paper is to study the effect of current on performance of EDM process of Allegheny Ludlum D2 Tool Steel (UNS T30402). The effect of varying the machining parameters on the machining responses such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (Ra) have been investigated. In this study, circular shape of copper was used as an electrode with surface area of 100mm². The experiments were repeated for three different values of pulse duration (100µs, 200µs and 400µs) with combination of three different values of discharge current (12A, 16A and 24A). It was found that the pulse duration and current give significant effect on MRR, EWR and Ra. An increase in the pulse durations causes an increase in the MRR and Ra, but a decrease in the EWR. Meanwhile, the effect of currents on EDM performance shows that the increasing currents led to an increase in the MRR, EWR and Ra.

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PENGARUH VARIABEL PEMOTONGAN TERHADAP KEAUSAN ELEKTRODA DAN BENDA KERJA PADA PROSES EDM

ROTASI ◽

10.14710/rotasi.16.4.9-16 ◽

2014 ◽

Vol 16 (4) ◽

pp. 9

Author(s):

Petrus Londa

Keyword(s):

Wear Rate ◽

Analysis Of Variance ◽

Material Removal Rate ◽

Orthogonal Array ◽

Material Removal ◽

Removal Rate ◽

Signal To Noise Ratio ◽

Electrode Wear ◽

Signal To Noise ◽

Electrode Wear Rate

Keausan elektroda pada proses EDM die sinking adalah peristiwa yang tidak dapat di hindari, namun dengan mengatur variabel pemotongan yang sesuai, diharapkan keausan yang terjadi se-minim mungkin sehingga dapat menjamin tingkat akurasi ukuran pada benda kerja yang di hasilkan. Pada penelitian ini di pilih metode Taguchi untuk menentukan variabel pemotongan yang optimum pada elektroda tembaga dan benda kerja dari bahan K460 (amutit S). Taguchi L9 orthogonal array, signal-to-noise ratio (S/N ratio) dan analysis of variance (ANOVA) dapat menentukan performa variabel proses EDM (PON, POFF, QDON dan GAP) dengan parameter yang di teliti adalah Electrode Wear Rate (EWR) dan Material Removal Rate (MRR). Hasil dari eksperimen tersebut di tampilkan dalam bentuk tabel-tabel dan grafik

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Multi-objective Optimization of PMEDM Process for Maximum Material Removal Speed and Minimum Electrode Wear Rate When Machining SKD11 Steel

Advances in Engineering Research and Application - Lecture Notes in Networks and Systems ◽

10.1007/978-3-030-92574-1_65 ◽

2022 ◽

pp. 623-633

Author(s):

Anh Tuan Nguyen ◽

Thi Tam Do ◽

Thu Quy Le ◽

Ngoc Huy Thinh Tran ◽

Hoang Anh Le ◽

...

Keyword(s):

Wear Rate ◽

Material Removal ◽

Electrode Wear ◽

Multi Objective Optimization ◽

Multi Objective ◽

Electrode Wear Rate

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Effect of Higher Peak Current and Pulse Duration on EWR of Copper Electrode when Electrical Discharge Machining (EDM) of Inconel 718

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.845.945 ◽

2013 ◽

Vol 845 ◽

pp. 945-949

Author(s):

S. Ahmad ◽

Mohd Amri Lajis

Keyword(s):

Wear Rate ◽

Pulse Duration ◽

Electrode Surface ◽

Inconel 718 ◽

Copper Electrode ◽

Work Piece ◽

Electrode Wear ◽

Peak Current ◽

Electrode Wear Rate ◽

Pulse On Time

In this work, the electrode wear rate (EWR) and electrode surface characteristic of copper electrode when EDM of Nickel Based Super Alloy, Inconel 718 at higher peak current and pulse duration were analyzed. Experiments were conducted using Inconel 718 as a work piece and copper as an electrode with a kerosene dielectric under different peak currents and pulse durations. Peak current, Ip within a range of 20A to 40A and pulse duration (or pulse on-time), ton within a range of 200μs to 400μs are selected as the main parameters. In this study, EWR were measured using digital weight balance (accuracy 0.01mg) and by using Scanning Electron Microscope (SEM), the surface texture of the electrode in order to evaluate the material deposited on the electrode surface. The results have shown that machining at a lowest peak current of 20A and highest pulse duration of 400μs yields the lowest electrode wear rate (EWR) of -0.01mm3/min. The pulse duration is significantly affecting the EWR. It also revealed that, the deposited of carbon and work piece material is occurred on the electrode surface for all machining conditions.

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Experimental Study During Electrical Discharge Machining of Reinforced Carbon Fiber Plastic Material

International Journal for Research in Applied Science and Engineering Technology ◽

10.22214/ijraset.2021.37589 ◽

2021 ◽

Vol 9 (8) ◽

pp. 1445-1451

Author(s):

Gaurav Pandey

Keyword(s):

Surface Roughness ◽

Carbon Fiber ◽

Wear Rate ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Removal Rate ◽

Fiber Composite ◽

Electrode Wear ◽

Machining Parameters

Abstract: The proper selection of machining conditions and machining parameter is an important aspect, before going to machine a carbon-fiber composite material by Die sinking electrical discharge machining (EDM). Because these conditions will determine such important characteristics as; Material removal rate (MRR), Electrode wears rate (EWR), and Surface roughness (R). The purpose of this work is to determine the optimal values of machining parameters of electrical discharge machine, while machining carbon-fiber-composite with copper electrode. The work has been based on the affect of four design factors: pulse current(Ip) supplied by power supply system of electrical discharge machine (EDM), pulse-on-time(TON), gap voltage(Vg) and duty cycle () on such characteristic like material removal rate (MRR), electrode wear rate(EWR), and surface roughness(Ra) on work-piece surface. This work has been done by means of the technique of design of experiment (DOE), which provides us to perform the above-mentioned analysis with small number of experiments. In this work, a L9 orthogonal array is used to design the experiment. The adequate selection of machining parameters is very important in manufacturing system, because these parameters determine the surface quality and dimensional accuracy of the manufactured part. The optimal setting of the parameters are determined through experiments planned, conducted and analyzed using the Taguchi method. It is found that material removal rate (MRR) reduces substantially, within the region of experimentation, if the parameters are set at their lowest values, while the parameters set at their highest values increases electrode wear rate (EWR). Keywords: EDM, Material removal rate, Surface roughness, Tool wear rate,

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Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406220906445 ◽

2020 ◽

Vol 234 (12) ◽

pp. 2459-2473 ◽

Cited By ~ 1

Author(s):

Jagtar Singh ◽

Gurminder Singh ◽

Pulak M Pandey

Keyword(s):

Wear Rate ◽

Material Removal Rate ◽

Electric Discharge ◽

Computer Aided Design ◽

Material Removal ◽

Removal Rate ◽

Copper Electrode ◽

Electrode Wear ◽

Electric Discharge Machining ◽

Electrode Wear Rate

The present investigation addresses the machining outcome of electric discharge machining using a rapid manufactured complex shape copper electrode. Developed rapid manufacturing technique using an amalgamation of polymer 3D printing and pressureless sintering of loose powder as rapid tooling has been used to fabricate copper electrode from the computer-aided design model of the desired shape. The fabricated electrode was used for the electric discharge machining of the D-2 steel workpiece. Central composite design was employed to study the electric discharge machining parameters (pulse duration, duty cycle and peak current) effect on the electric discharge machining characteristics such as material removal rate, electrode wear rate and cavity dimensional deviation as overcut from electrode computer-aided design model. Analysis of variance was executed to attain significant parameters along with interactions. Peak current was found to be the utmost dominating parameter for three responses. The high percentage of carbon was observed on the electrode surface after electric discharge machining at the high level of pulse duration and resulted in low electrode wear rate. The high percentage of dimensional deviation was noticed at the maximum duty cycle and maximum peak current by the substantial interactions. Genetic algorithm-based multi-objective optimization was employed for the electric discharge machining parameters optimization to maximize material removal rate, minimize electrode wear rate and dimensional deviation. The multi-feature complex copper electrode was fabricated and used for electric discharge machining as the case study to check the efficacy of the optimized process. It was witnessed that the process was competent to fabricate complex shape cavity as per the desired computer-aided design model shape with efficient material removal rate and electrode wear rate.

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