Electro-discharge Machining Performance of Ti–6Al–4V Alloy: Studies on Parametric Effect and Phenomenon of Electrode Wear

2018 ◽  
Vol 44 (2) ◽  
pp. 1553-1568 ◽  
Author(s):  
Manoj Kumar ◽  
Saurav Datta ◽  
Rajneesh Kumar
Keyword(s):  
Electrode Wear ◽  
Machining Performance ◽  
Electro Discharge Machining ◽  
Parametric Effect

scholarly journals Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 617
Author(s):  
Jing Li ◽  
Wanwan Chen ◽  
Yongwei Zhu
Keyword(s):  
Ultrasonic Vibration ◽  
Orthogonal Experiment ◽  
Spindle Speed ◽  
Machining Efficiency ◽  
Matrix Composites ◽  
Two Dimensional ◽  
Machining Performance ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Workpiece Vibration

Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.

scholarly journals A study of micro-electro discharge machining electrode wear

2007 ◽  
Vol 221 (5) ◽  
pp. 605-612 ◽  
Author(s):  
D T Pham ◽  
A Ivanov ◽  
S Bigot ◽  
K Popov ◽  
S Dimov
Keyword(s):  
Electrode Wear ◽  
Micro Edm ◽  
Volumetric Wear ◽  
Factors Affecting ◽  
Electro Discharge Machining ◽  
Electrode Shape ◽  
Compensation Methods ◽  
Geometrical Information ◽  
Edm Drilling ◽  
Edm Process

This paper studies the influence of factors contributing to electrode wear during the micro-electro discharge machining (EDM) process. The paper proposes a method for calculating the volumetric wear ratio based only on geometrical information obtained from the process. The objective of the work is to investigate the suitability of micro-EDM electrode wear compensation methods. Electrode shape deformation and random variations in the volumetric wear are studied as two main factors affecting the applicability of wear compensation methods as well as indicating the accuracy achievable with micro-EDM. EDM drilling and EDM milling are regarded as separate processes as they require different approaches in investigating and implementing the results of the study.

Electro-discharge machining performance of TiCN-based cermets

2007 ◽  
Vol 25 (4) ◽  
pp. 293-299 ◽  
Author(s):  
B.V. Manoj Kumar ◽  
J. Ramkumar ◽  
Bikramjit Basu ◽  
S. Kang
Keyword(s):  
Machining Performance ◽  
Electro Discharge Machining

Wire Electro Discharge Machining of Al/SiC Metal Matrix Composite

2011 ◽  
Vol 121-126 ◽  
pp. 564-567
Author(s):  
Bao Ji Ma ◽  
Yu Quan Zhu ◽  
Xiao Li Jin
Keyword(s):  
Surface Roughness ◽  
Current Pulse ◽  
Pulse Duration ◽  
Cutting Speed ◽  
Machining Performance ◽  
Peak Current ◽  
Positive Effects ◽  
Electro Discharge Machining ◽  
Input Variables ◽  
Pulse On Time

The machining characteristics of SiC/Al composite using wire electro discharge machining (WEDM) were investigated in this study. Material cutting speed and surface roughness value were adopted to evaluate the machinability. Peak current, pulse on time, pulse duration and working voltage were selected as the input variables to investigate the machining performance. Effects of input variables on the cutting speed and surface roughness were experimentally tested. Peak current, pulse on time and working voltage were confirmed to have positive effects on cutting speed and surface roughness value. Whereas the cutting speed and surface roughness value decrease with the increase of pulse duration.

scholarly journals EDM PROCESS PARAMETER OPTIMIZATION FOR EFFICIENT MACHINING OF INCONEL-718

2020 ◽  
Vol 18 (3) ◽  
pp. 473
Author(s):  
Ankit Singh ◽  
Ranjan Kumar Ghadai ◽  
Kanak Kalita ◽  
Prasenjit Chatterjee ◽  
Dragan Pamučar
Keyword(s):  
Wear Rate ◽  
Inconel 718 ◽  
Removal Rate ◽  
Subjective Evaluation ◽  
Fluid Pressure ◽  
Objective Evaluation ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Machining Performance ◽  
Edm Process

In the present work, multi-response optimization of electro-discharge machining (EDM) process is carried out based on an experimental analysis of machining superalloy Inconel-718. The study aims at optimizing and determining an optimal set of process variables, namely discharge current (), pulse-on duration () and dielectric fluid-pressure () for achieving optimal machining performance in EDM. Nine independent experiments based on L9 orthogonal array are carried out by using tungsten as the electrode. The productivity performance of the EDM process is measured in terms of material removal rate (MRR) and its cost parameter is measured in terms of tool wear rate (TWR) and electrode wear rate (EWR). The TOPSIS is used in conjunction with five different criterion weight allocation strategies— (namely, mean weight (MW), standard deviation (SDV), entropy, analytic hierarchy process (AHP) and Fuzzy). While MW, SDV and entropy are based on the objective evaluation of the decision-maker (DM), the AHP can model the DM’s subjective evaluation. On the other hand, the uncertainty in the DM’s evaluation is analyzed by using the fuzzy weighing approach.

Evaluation of Electrical Discharge Machining Performance on Al (6351)–SiC–B4C Composite

2019 ◽  
pp. 109-124
Author(s):  
Uthayakumar M. ◽  
Suresh Kumar S. ◽  
Thirumalai Kumaran S. ◽  
Parameswaran P.
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machined Surface ◽  
Output Performance ◽  
B4c Particles

Electrical discharge machining (EDM) process is a non-conventional machining process used for the material which are difficult to machine. In this research work, an attempt has been made to determine the influence of Boron Carbide (B4C) particles on the machinablity of the Al (6351) alloy reinforced with 5 wt. % Silicon Carbide (SiC) Metal Matrix Composite (MMC) through EDM. Influence of machining parameters such as pulse current (I), pulse on time (Ton), duty factor (τ), and gap voltage (V) on affecting the output performance characteristics namely Electrode Wear Ratio (EWR), Surface Roughness (SR) and Power Consumption (PC) which are studied. The result shows that the addition of B4C particles significantly affects the machinablity of the composite, with a contribution of 1.6% on EWR, 3.5% on SR and 19.8% on PC. The crater, recast layer formation, and Heat Affected Zone (HAZ) in the machined surface of the composite are also reported in detail.

Multi Objective Optimization of Electro Discharge Machining of Resin Bonded Silicon Carbide

2011 ◽  
Vol 110-116 ◽  
pp. 1556-1560
Author(s):  
R. Venkataraman
Keyword(s):  
Silicon Carbide ◽  
Gas Turbines ◽  
Operating Conditions ◽  
Machining Process ◽  
Pareto Optimal ◽  
Electrode Wear ◽  
Pareto Optimal Front ◽  
Multi Objective ◽  
Electro Discharge Machining ◽  
Pulse On Time

This work is aimed at optimizing the various parameters of the electro discharge machining process in order to Maximize material removal rate (MRR) and Minimize electrode wear rate (EWR) for machining silicon or resin bonded silicon carbide, which is widely used in various applications like high-temperature gas turbines, bearings, seals and linings of industrial furnaces. The five parameters being optimized are intensity supplied by the generator of the EDM machine, open voltage, pulse on time, duty cycle and pressure of flushing fluid. The polynomial models for MRR and EWR proposed by Luis, Puertas and Villa [1] in terms of the five input parameters was used for formation of the objective function. Optimization was carried out using the multi objective genetic algorithm, which is a heuristic search technique that mimics natural selection. A Pareto-optimal front was obtained using this technique, and the points lying on this front represent the set of optimal solutions for the optimization problem. The resultant Pareto– optimal front can be used to select the appropriate operating conditions depending on the specific MRR, EWR or combination requirements.

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