Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid

2020 ◽  
Vol 42 (10) ◽  
Author(s):  
Rajesh Bajaj ◽  
Amit Rai Dixit ◽  
Arun Kumar Tiwari
Keyword(s):  
Electric Discharge ◽  
Performance Enhancement ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Electric Discharge Machining

Experimental Investigation of Sunflower Oil as Dielectric Fluid in Die Sinking Electric Discharge Machining Process

2019 ◽  
Vol 969 ◽  
pp. 715-719
Author(s):  
G. Gowtham Reddy ◽  
Balasubramaniyan Singaravel ◽  
K. Chandra Shekar
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Dielectric Fluids ◽  
Pulse On Time ◽  
Pulse Off Time

Electric Discharge Machining (EDM) is used to machine complex geometries of difficult to cut materials in the area of making dies, mould and tools. Currently, hydrocarbon based dielectric fluids are used in EDM and which plays major role for material removal and it emits harmful emission. In this work, vegetable oil is attempted as dielectric fluid and their performance are studied during processing of AISI P20 steel. The effect of pulse on time (Pon) , pulse off time (Poff), and current (A) on Material Removal Rate (MRR), Tool wear rate (TWR) and surface roughness (SR) are analyzed. The result showed that vegetable oils are given good machining performance than conventional dielectric fluids. These proposed dielectric fluids are biodegradable eco friendly and enhance sustainability in EDM process.

Effect of the Surfactant Concentration on Sinking Electric Discharge Machining Performance with Water-in-Oil Emulsion as Dielectric

2011 ◽  
Vol 189-193 ◽  
pp. 3153-3157
Author(s):  
Yan Zhen Zhang ◽  
Yong Hong Liu ◽  
Ren Jie Ji ◽  
Bao Ping Cai
Keyword(s):  
Physical Properties ◽  
Electric Discharge ◽  
Surfactant Concentration ◽  
Emulsion Stability ◽  
Experimental Results ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Oil Emulsion ◽  
The Stability ◽  
Water In Oil Emulsion

In this paper, the EDM performance of water-in-oil (W/O) emulsions dielectric with different surfactant concentration is investigated by correlated to its physical properties, such as viscosity and droplets size, which is predominantly determined by the surfactant concentration. Experimental results show that the stability of the W/O emulsions increases with increasing surfactant concentration, whereas the EDM performance deteriorates with increasing surfactant concentration. So, taking a comprehensively consideration of the emulsion stability and EDM performance, the concentration of surfactant must be appropriately selected.

scholarly journals Near Dry and Powder Mixed Near Dry Electric Discharge Machining

2019 ◽  
Vol 9 (1) ◽  
pp. 2021-2025
Keyword(s):  
Electric Discharge ◽  
Removal Rate ◽  
Vital Role ◽  
Experimental Result ◽  
Experimental Comparison ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Hard Materials ◽  
Dry Edm ◽  
Conventional Machining

Electric discharge machining (EDM) is a non conventional machining method to fabricate very tough and hard materials. Although EDM has played a vital role in machining industry but with advancement of technology, alternative advanced methods of machining have been evolved such as near dry EDM (ND-EDM) and powder mixed near dry EDM (PMND-EDM). These technologies have been proven more efficient than traditional EDM in terms of machining performance characteristics such as higher material removal rate (MRR), better surface finish (Ra) and low tool wear rate (TWR) with high tolerance quality products. In this study an approach has been made to draw experimental comparison between ND-EDM and PMND-EDM in terms of MRR, SR and TWR. The experimental result and analysis revealed that PMND-EDM was better machining method than ND-EDM as in the former technique, the M RR increased by 45.04 % while SR and TWR reduced by 45.33 % and 60.60% respectively

scholarly journals Multi-Objective Optimization of Aluminium Powder-mixed EDM process using GRA and TOPSIS Technique based on Fuzzy AHP approach

2021 ◽  
Vol 19 (5) ◽  
pp. 437-447
Author(s):  
Fahad Kazi ◽  
C.A Waghmare ◽  
M.S Sohani
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Fuzzy Ahp ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Electric Discharge Machining ◽  
Aluminium Powder ◽  
Pulse On Time

Electric discharge machining is an advanced machining technique. Spark is initiated between the tool and work piece interface which has a gap between them. Low material removal rate as well as low surface finish is a major concern of this process. Therefore, Powder mixed electric discharge machining is developed. In PMEDM process, powders like silicon, aluminium, chromium, manganese, etc. are circulated along with dielectric fluid in a particular proportion. In this present study, aluminium powder is mixed in the dielectric fluid. The responses such as material removal rate, tool wear rate and surface roughness are measured by considering current, pulse on time and aluminium powder concentration as process parameters. Response surface methodology along with Fuzzy AHP TOPSIS and Grey relational analysis are used for optimization.

Study the Surface Characteristics of Cryogenically Treated Tool-Electrodes in Powder Mixed Electric Discharge Machining Process

2014 ◽  
Vol 808 ◽  
pp. 19-33 ◽  
Author(s):  
Sanjeev Kumar ◽  
Rupinder Singh ◽  
Ajay Batish ◽  
T.P. Singh
Keyword(s):  
Electric Discharge ◽  
Surface Characteristics ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Material Transfer ◽  
Electric Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

The present experimental study has been focused to evaluate surface characteristics of cryogenically-treated (shallow/deep) tool-electrodes using powder mixed electric discharge machining. Due to the continuously growing demand of complex and precise parts, tool-electrodes have its own importance, because quality of the machined parts depends upon the surface quality of electrode. On the analogy, eighteen experiments were performed based on L18orthogonal array of Taguchi’s methodology, which consist eight input parameters. Analysis of variance (ANOVA) was employed to designate the level of significance of input parameters. Electrode material has maximum influence followed by the current and pulse on-time on electrode finish. The combination of optimum factor’s level of identified parameters was determined using Taguchi’s technique for single response. Confirmation experiments were conducted using suggested optimal parameters with its respective level to minimize the tool-electrode surface roughness. Surface characteristics of tool-electrodes were analyzed using Scanning Electron Microscope (SEM) and Energy Dispersive Spectrograph (EDS) followed by X-ray diffraction (XRD) on selected samples. The results exposed that significant material transfer from workpiece and powder mixed dielectric fluid in compound form on the tool surface.

SKD 61 Material Surface Treatment with Electric Discharge Machining Using Cu, CuCr & Graphite Electrodes and Dielectric Fluid Jatrophacurcas

2013 ◽  
Vol 789 ◽  
pp. 307-312
Author(s):  
Triyono ◽  
Dedi Priadi ◽  
Eddy S. Siradj ◽  
Winarto
Keyword(s):  
Surface Treatment ◽  
Electric Discharge ◽  
Removal Rate ◽  
White Layer ◽  
Material Surface ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Graphite Electrodes ◽  
Edm Process

The emergence of white layer in each process of Electric Discharge Machining (EDM) becomes the focus of attention of the experts. It is harder than the base metal would be advantageous to withstand friction engine components, such as the plastic molding industry. From various studies it has been reported that the increase in the value of hardness of white layer either due to migration of the electrode material and dielectric fluid to the white layer. This paper discusses the influence of electrodes Cu, CuCr and graphite as well as jatrophacurcas dielectric fluid to the surface of the material SKD 61, microhardness of the white layer, Tool Wear Rate (TWR) of Material Removal Rate (MRR), Surface roughness (Ra) and the microstructure. Initial studies conducted are the transesterification and characterization of jatrophacurcas to determine the dielectric strength and the content of metal elements. Furthermore, the EDM testing is done to dies steel of SKD 61 using the electrodes of Cu, CuCr and Graphite. The use of jatrophacurcas yield the best MRR when using Graphite electrodes followed Cu last CuCr. While the smallest TWR produced by Cu electrode, CuCr and then the highest is Graphite. The relative wear which is the ratio TWR with MRR, for the three types of electrodes is always great at a small current then decreases and then tends to be stable with the increase of electric current. Jatrophacurcas for the three types of electrodes provide higher TWR than kerosene. This means that migration of materials is beneficial because larger material, but in terms of the geometric accuracy of the product can lead to decreasing of dimensional tolerances. Vickers hardness values of white layer is achieved by CuCr electrodes, Graphite lowest. Microstructural observation results of EDM white layer using graphite electrodes produce a more uniform thickness than the white layer using Cu and CuCr electrodes. The conclusion of this study that jatrophacurcas can be used as a dielectric fluid in EDM process, because electrode wear during EDM process is relatively high compared with kerosene that is mean more profitable in the surface treatment process of dies steel of SKD 61.

Effect of Materials on the Mechanism of Electric Discharge Machining (E.D.M.)

1983 ◽  
Vol 105 (2) ◽  
pp. 132-138 ◽  
Author(s):  
A. Erden
Keyword(s):  
Electric Discharge ◽  
Particle Concentration ◽  
Electrode Materials ◽  
Tool Material ◽  
Mathematical Expression ◽  
Machining Process ◽  
Time Lags ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Workpiece Material

Electric Discharge Machining process is investigated both theoretically and experimentally to determine the effects of electrode materials on the machining performance. For this purpose a single and isolated spark is physically and mathematically modelled, and its three phases; viz., Breakdown, Discharge and Erosion are investigated. Resolidified electrode materials as suspended particles in the dielectric liquid are found to be the most significant factor in the breakdown phase. Mathematical expressions relating the time lags to particle concentration are given which can be used to determine the effects of particle concentration on the machining performance. Discharge properties are shown to be dependent on the discharge medium which includes vapours of the electrode materials. The polarity effect has been studied both theoretically and experimentally. Some qualitative explanation is given for the erosion phase. Importance of electrical forces is discussed and a simple mathematical expression is given for the erosion phase. It is concluded that optimum machining conditions can only be obtained by proper selection of the tool material, workpiece material and discharge medium since they affect the initiation and development of the discharge and erosion of electrode materials.

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