Analysis and Optimization of Tool Wear Rate in Magnetic Field-Assisted Powder-Mixed Electrical Discharge Machining of Al6061 Alloy Using TLBO

2019 ◽  
pp. 485-495
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Wear Rate ◽  
Al6061 Alloy

Fabrication and experimental investigation of magnetic field assisted powder mixed electrical discharge machining on machining of aluminum 6061 alloy

2019 ◽  
Vol 233 (12) ◽  
pp. 2283-2291 ◽  
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Pulse On Time

Magnetic field assisted powder mixed electrical discharge machining is a hybrid machining process with suitable modification in electrical discharge machining combining the use of magnetic field and fine powder in the dielectric fluid. Aluminum 6061 alloy has found highly significance for the advanced industries like automotive, aerospace, electrical, marine, food processing and chemical due to good corrosion resistance, high strength-to-weight ratio, ease of weldability. In this present work, magnetic field assisted powder mixed electrical discharge machining setup was fabricated and experiments were performed using one factor at a time approach for aluminum 6061 alloy. The individual effect of machining parameters namely, peak current, pulse on time, pulse off time, powder concentration and magnetic field on material removal rate and tool wear rate was investigated. The effect of peak current was found to be dominant on material removal rate and tool wear rate followed by pulse on time, powder concentration and magnetic field. Increase in material removal rate and tool wear rate was observed with increase in peak current, pulse on time and a decrease in pulse off time, whereas, for material removal rate increases and tool wear rate decreases up to the certain value and follow the reverse trend with an increase in powder concentration. Material removal rate was increased and tool wear rate was decreased with increase in magnetic field.

CHARACTERIZATION OF ZrB2-SiC COMPOSITES WITH AN ANALYTICAL STUDY ON MATERIAL REMOVAL RATE AND TOOL WEAR RATE DURING ELECTRICAL DISCHARGE MACHINING

2016 ◽  
Vol 40 (3) ◽  
pp. 331-349 ◽  
Author(s):  
S. Sivasankar ◽  
R. Jeyapaul
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Relative Density ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Tool Materials

This research work concentrates on Electrical Discharge Machining (EDM) performance evaluation of ZrB2- SiC ceramic matrix composites with different tool materials at various machining parameters. Monolithic ZrB2 possesses lower relative density (98.72%) than composites. ZrB2 with 20 Vol.% of SiC possesses 99.74% of the relative density with improved hardness values. Bend strength and Young’s modulus increase with SiC addition until it reaches 20 Vol% and then decreasing. EDM performance on tool materials of tungsten, niobium, tantalum, graphite and titanium at various levels of pulse on time and pulse off time are analyzed. Graphite produces the best Material removal rate (MRR) for all the workpieces. Tool wear rate decreases with melting point and thermal conductivity of the tool material.

Analysis of MRR and TWR on OHNS Die Steel with Different Electrodes Using Electrical Discharge Machining

2016 ◽  
Vol 22 ◽  
pp. 112-120 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Tool Wear Rate

Electrical Discharge Machining is a machining method primarily used for hard metals or those that are impossible to be machined with traditional techniques. The experimental investigation of material removal rate and tool wear rate during machining of oil hardened non-shrinking steel with brass and copper electrodes using EDM machine was carried out in this paper. This investigation presents the analysis and evaluation of heat affected zones and surface finish of the work piece using different tool electrodes and varying the machine parameters. The commercial grade kerosene oil has been used as dielectric fluid. The effect of various important EDM parameters such as discharge current (Ip) 2 to12A, pulse duration (Ton and Toff) and sparking voltage (V) of 80±5% have been used to yield the response in terms of Material Removal Rate (MRR) and Tool Wear Rate (TWR). Further a detailed analysis of the heat affected regions was also been carried out by using scanning electron microscopy.

PENGARUH PARAMETER PROSES EDM DIE SINKING TERHADAP LAJU PELEPASAN BAHAN DAN LAJU KEAUSAN ELEKTRODA

2019 ◽  
Vol 1 (2) ◽  
pp. 105-112
Author(s):  
Nafsan Upara ◽  
Dimas Anugrah Destianto
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate

Electrical Discharge Machining (EDM) merupakan pemesinan nonkonvensional yang memanfaatkan proses konversi listrik dan panas, dimana energi listrik digunakan untuk memunculkan loncatan bunga api dan proses pelepassan bahan terjadi akibat energi panas yang ditimbulkan dari bunga api tersebut.Keausan elektroda pada proses EDM die sinking merupakan peristiwa yang tidak dapat di hindari, namun dengan mengatur parameter pemotongan yang sesuai, diharapkan keausan yang terjadi pada elektroda se-minim mungkin dan pemakanan benda kerja semaksimal mungkin sehingga didapati tingkat akurasi ukuran pada benda kerja. Pada penelitian ini menggunakan metode Taguchi  dengan L8 orthogonal array memakai elektroda bahan tembaga dan benda kerja material SKS 3. S/N ratio dan ANOVA menentukan performa parameter proses EDM dengan respon yang di teliti adalah Material Removal Rate (MRR) dan Tool Wear Rate (TWR). Hasil dari eksperimen tersebut menghasilkan parameter optimum Aruslevel 2= 6 A; Ponlevel 1=100 µs dan Pofflevel 1=50µs.

Mathematical Model for Wear Rate of Negative Graphite Electrode in Electrical Discharge Machining on Ti-5A1-2.5Sn

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman ◽  
K. Kadirgama ◽  
A. R. Ismail
Keyword(s):  
Mathematical Model ◽  
Wear Rate ◽  
Tool Wear ◽  
Linear Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Workpiece Material ◽  
Non Linear

There are several electrical and non-electrical factors having the significant effect on tool wear in electrical discharge machining (EDM). It is very difficult to select the parameters correctly. Likewise, the tool wear rate is changed dramatically with workpiece material and electrode material. Until now no attempt is appeared that yields the tool wear characteristics in EDM on Ti-5Al-2.5Sn retaining Graphite as electrode. Thus, in this study a mathematical model is developed to predict the tool wear rate which will provide the opportunity of proper selection of the EDM parameters and make the EDM cost effective. To model both the linear and non-linear equation is applied using the experimental data which are obtained performing the experimentation as design of experiment. The developed model has been verified through analysis of variance (ANOVA). The second-order non-linear model is found as appropriate as compared with a linear model. It is evidenced that the proposed model can effectively predict the tool wear rate (TWR) and adequately explains the variation in the machining parameters on TWR.

Research on Tool Wear Rate of Powder Mixed near Dry Electrical Discharge Machining

2013 ◽  
Vol 652-654 ◽  
pp. 2222-2227 ◽  
Author(s):  
Xue Bai ◽  
Qin He Zhang ◽  
Ting Yi Yang ◽  
Jian Hua Zhang ◽  
Jing Tan
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Wear Rate ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Dry Electrical Discharge Machining

Powder mixed near dry electrical discharge machining (PMND-EDM) is one of the novel EDM processes, which uses gas-liquid-powder mixture as the dielectric medium. The tool wear rate (TWR) in PMND-EDM is researched based on single factor experiments. Effects of process parameters, such as peak current, pulse on time, pulse off time, flow rate, powder concentration, tool rotational speed and air pressure, on TWR are found out. TWR increases with the increase of peak current. TWR decreases with increasing of pulse on time. TWR increases firstly and then decreases while pulse off time increases. Increase of flow rate results in the increase of TWR. With the increase of powder concentration, TWR increases firstly and then decreases. Existence of tool rotation facilities decrease of TWR, however, further increase of rotational speed leads to increase of TWR. Increase of air pressure leads to lower TWR.

Experimental investigation of the effect of tool material on the performance of AISI 4140 steel in the rotary near dry electrical discharge machining

2020 ◽  
Vol 234 (4) ◽  
pp. 308-317
Author(s):  
Fereydoon Rajabinasab ◽  
Vahid Abedini ◽  
Mohammadjafar Hadad ◽  
Ramezanali Hajighorbani
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Material ◽  
Tool Wear Rate ◽  
Dry Electrical Discharge Machining

This research conducts in three sections. The first section studies the effect of tool materials and gases on rotary workpiece electrical discharge machining. During the experiments, the effects of three kinds of tool materials (Cu, Cu-Cr, and Cu-Sn) and three types of industrial gases (air, argon, and CO2) on the material removal rate, tool wear rate, and workpiece surface roughness are investigated. The second is a comparison between rotary workpiece, rotary tool, and the fixed workpiece by choosing the appropriate tool material and gas in order to observe the effect of workpieces rotation on the process. Finally, another comparison has been done between wet electrical discharge machining and near dry electrical discharge machining of the fixed workpiece in order to study the effect of the dielectric. The results show the copper tool has the best performance compared with other tools. Scanning electron microscopy output shows the Cu-Sn tool creates shallow micro-cracks on the surface. Air and CO2 gases have the higher material removal rate in low current, but argon has better function than other gases in high current. In addition, a rotational speed causes an increase in material removal rate and tool wear rate and surface roughness decrease in near dry electrical discharge machining. The level of tool wear rate has decreased by 14% in the rotary workpiece compared with the rotary tool.

Optimization the Machining Parameters of Electro Chemical Discharge Machining of NiTi Shape Memory Alloys

2021 ◽  
Vol 1039 ◽  
pp. 117-126
Author(s):  
Shahad Ali Hammood ◽  
Haydar Abdul Hassan Al-Ethari ◽  
Abdolreza Rahimi
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Solution Concentration ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Conventional Methods ◽  
Taguchi’S Design Of Experiments

The electrochemical discharge machining (ECDM) is a combination effect of electrochemical machining in which metal is removed through the electrochemical process and electrical discharge machining in which metal is removed by rapid current discharges between two electrodes which are separated by a dielectric liquid and subject to an electric voltage. Difficulty of machining nickel titanium alloys by conventional methods such as; the significant tool wear, the need of highly experienced operators, and an excessive degradation in the material performance due to the high thermal and mechanical effects of these methods. For these, reasons non-conventional methods such as electrical discharge machining and electro chemical machining are often used to fabricate NiTi alloys with better machining results. The experiments were conducted with various conditions of voltage (50,60,70 and 80)V, dielectric solution concentration (30 and 40% of NaOH) and nanoparticles silver, and copper content (0.5% Cu, 0.5% Ag, 0.5% Cu and Ag) in the (55% Ni-45%Ti) alloy samples. The machining experiments were designed according to Taguchi's design of experiments (L32). Grey relational analysis was used to optimize the responses of the ECDM process. Material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) represent the response parameters for machining of the alloy samples prepared by the powder metallurgy route. To achieve the objectives of this research work MiniTab17 software was employed. The optimal conditions were: voltage of 50V, solution concentration of 40% and the sample (NiTi+0.5%Cu+0.5%Ag) have the highest effect on machining characteristics with MRR value of 0.04991mg/sec., tool wear rate value of 0.00125mg/sec., and surface roughness of 0.0117μm.

scholarly journals Study of the effects of process parameters on tool wear rate in powder mixed electrical discharge machining by Taguchi method

2018 ◽  
Vol 20 (K7) ◽  
pp. 55-60
Author(s):  
Phan - Nguyen Huu
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Taguchi Method ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Wear Rate ◽  
Machined Surface ◽  
Powder Concentration ◽  
Pulse On Time

There have been various attempts to improve the surface finish after Electrical Discharge Machining (EDM) by polishing and other means. But if it is possible to improve the surface during machining it will shorten the machining time. From this viewpoint powder mixed EDM (PMEDM) is one of these processes. PMEDM not only imparts fine machined surface finish but also modifies the machined surface. However, it is necessary to understand the mechanism of PMEDM process. In this study, influence of process parameters to tool wear rate (TWR) of PMEDM using titanium (Ti) powder is presented. The objective of the study is to evaluate the main effects of workpiece material, tool material, polarity, pulse-on time, intensity of discharge, pulse-off time, and powder concentration on the TWR in PMEDM. They carried out the investigation based on the Taguchi method involving seven control factors with three levels for an orthogonal array L27 (1313).The results indicated that electrode material, electrode polarity, pulse on time, current and powder concentration were the most significant parameters that influenced the TWR. This result will be the basis for selecting the factors in further optimization studies.  

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