Development of an inversion model for establishing EDM input parameters to satisfy material removal rate, electrode wear ratio and surface roughness

2011 ◽  
Vol 57 (1-4) ◽  
pp. 189-201 ◽  
Author(s):  
Horacio T. Sánchez ◽  
Manuel Estrems ◽  
Félix Faura
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Inversion Model ◽  
Wear Ratio ◽  
Input Parameters

Effect of Surfactant on EDM of Low Conductivity Reaction-Bonded Silicon Carbide

2016 ◽  
Vol 701 ◽  
pp. 107-111
Author(s):  
Muhammad Raziman Abdul Razak ◽  
Pay Jun Liew ◽  
Nur Izan Syahriah Hussein ◽  
Qumrul Ahsan
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Weight Percentage ◽  
Wear Ratio ◽  
Optimum Weight ◽  
Span 80

This work was focused on improving machining performance of reaction-bonded silicon carbide (RB-SiC) ceramic material using an electrical discharge machine (EDM) with the aid of surfactant. The changes of material removal rate, electrode wear ratio and surface roughness were investigated under two different surfactants, namely Span 20 and Span 80. The surfactant was mixed with carbon nanofiber (CNF) and EDM oil prior to the experiment. Then, the mixture was homogenized in an ultrasonic homogenizer for 35 minutes. In order to investigate the effect of surfactant, different weight percentages which is 0.4wt%, 0.6wt% and 0.8wt% of surfactant were used. The experimental results show that with the addition of Span 20 and Span 80, the electrode wear ratio was decreased with the increased of surfactants weight percentage. Surface finish also can be improved by adding surfactant in the dielectric fluid. The lowest surface roughness was achieved at a surfactant weight percentage of 0.4wt%. The optimum weight percentage for obtaining the highest material removal rate (MRR) was 0.6wt% for both surfactants. In comparison, CNF added with surfactant Span 80 was more effective to improve the machining efficiency of RB-SiC compared to surfactant Span 20, at the optimum weight percentage 0.6wt%.

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

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,

Influence of Workpiece Shape on MRR and EWR in EDM of Steel

2014 ◽  
Vol 903 ◽  
pp. 51-55 ◽  
Author(s):  
Alexis Mouangue Nanimina ◽  
Ahmad Majdi Abdul Rani ◽  
Mohd Amri Lajis ◽  
Turnad Lenggo Ginta ◽  
T.V.V.L.N. Rao
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Electrode Wear ◽  
Wear Ratio ◽  
Flat Shape ◽  
Dielectric Flushing ◽  
Edm Process

Shape of workpiece, electrode orientation and flushing system play important role in electrical discharge machining (EDM) process. Low material removal rate and relatively high electrode wear ratio are some of the disadvantages of EDM process. This can be due to the flushing modes. Workpiece shape has a significant effect in effectiveness of dielectric flushing flow and orientation during EDM process. This research work is conducted to analyze the influence of various workpiece shapes. Square cavity, L shape, flat shape and U shape were machined with same cross-section electrode material. Test parameters are material removal rate (MRR) and electrode wear ratio (EWR). Experiment results show slight difference in MRR and EWR values for different shapes. U shape presents the highest MRR and the lowest EWR occurs in flat shape compared to cavity and L shapes. It can be concluded that flat and U shapes result in good EDM machining quality due to good dielectric flow and flushing conditions in the area of EDM machining.

scholarly journals To study the effect of grinding parameters on surface roughness and material removal rate of cylindrical grinding of heat treated en 47 steel

2016 ◽  
Vol 45 (2) ◽  
pp. 81-88
Author(s):  
Mukesh Kumar ◽  
Sukhjinder Singh ◽  
Khushdeep Goyal
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Experimental Design ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Steel Material ◽  
Heat Treated ◽  
Input Parameters ◽  
Significant Factors

This research paper attempts to optimize the effect of input parameters to minimize surface roughness and maximize the material removal rate in cylindrically grinding of EN 47 steel material. Taguchi L18 (2)¹, (3)5 orthogonal array or mixed level of parameters have been applied to experimental design with the help of mini tab software. The result reveals that grain size and work speed are the most significant factors to influence material removal rate and surface roughness. The optimum set of input parameters for maximizing the material removal rate and optimum surface roughness have also been found

Optimization by Grey Relational Analysis of EDM Parameters on Machining Ti-6Al-4V

2010 ◽  
Vol 139-141 ◽  
pp. 540-544 ◽  
Author(s):  
Zhi Ping Xie ◽  
Ji Ming Zheng ◽  
Bian Li Quan
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Grey Relational Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Relational Analysis ◽  
Wear Ratio ◽  
Grey Relational

In this paper, parameter optimization of the electrical discharge machining process to Ti–6Al–4V alloy considering the multiple responses using the Taguchi method and grey relational analysis is reported. The multi-response optimization of the process parameters are material removal rate (MRR) and electrode wear rate (EWR). The machining parameters including discharge current, voltage, pulse on time and duty factor. Experiment based on the orthogonal array, The optimized process parameters simultaneously leading to a lower electrode wear ratio and higher material removal rate are then verified through a confirmation experiment. The experimental result for the optimal setting shows that there is considerable improvement in the process. The validation experiments show an improved electrode wear ratio of 2.8%, material removal rate of 45.8% when the Taguchi method and grey relational analysis are used.

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

2014 ◽  
Vol 2014 ◽  
pp. 1-16 ◽  
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.

scholarly journals Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Energies ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 38 ◽  
Author(s):  
Misbah Niamat ◽  
Shoaib Sarfraz ◽  
Wasim Ahmad ◽  
Essam Shehab ◽  
Konstantinos Salonitis
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Multi Objective Optimization ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

Sign in / Sign up

Export Citation Format

Share Document