Effect on crystalline structure of AISI M2 steel using copper electrode through material removal rate, electrode wear rate and surface finish

Measurement ◽  
2015 ◽  
Vol 61 ◽  
pp. 305-319 ◽  
Author(s):  
Gangaram Mandaloi ◽  
Subhash Singh ◽  
Pradeep Kumar ◽  
Kaushik Pal
Keyword(s):  
Wear Rate ◽  
Crystalline Structure ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Electrode Wear Rate

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

2020 ◽  
Vol 234 (12) ◽  
pp. 2459-2473 ◽  
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.

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

ROTASI ◽  
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

scholarly journals Effect of Different Dielectrics on Material Removal Rate, Electrode Wear Rate and Microstructures in EDM

Procedia CIRP ◽  
2017 ◽  
Vol 60 ◽  
pp. 2-7 ◽  
Author(s):  
Misbah Niamat ◽  
Shoaib Sarfraz ◽  
Haris Aziz ◽  
Mirza Jahanzaib ◽  
Essam Shehab ◽  
...  
Keyword(s):  
Wear Rate ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electrode Wear Rate

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 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,

Study on Electrical Discharge Machining Characteristics of Electrically Conductive Ceramics

2009 ◽  
Vol 407-408 ◽  
pp. 636-639 ◽  
Author(s):  
Hai Wang ◽  
Akira Okada ◽  
Takafumi Uwano ◽  
Yoshiyuki Uno ◽  
Habib Sameh
Keyword(s):  
Wear Rate ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Hardness ◽  
Titanium Boride ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Electrically Conductive ◽  
Electrode Wear Rate ◽  
Conductive Ceramics

This paper deals with EDM characteristics of newly develops electrically conductive ceramics. Titanium boride (TiB2) is widely used as die and mold materials because of its high hardness, high-temperature resistance and so on. The EDM characteristics of the titanium boride, such as electrode wear rate, removal rate and surface roughness were investigated. Experimental results show that EDM with low electrode wear rate is possible when copper electrode is used with positive polarity. The removal rate becomes much higher when graphite electrode is used with negative polarity.

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