Investigation on effect of process parameter on surface integrity during electrical discharge machining of NiTi 60

2020 ◽  
Vol 16 (6) ◽  
pp. 1385-1394
Author(s):  
Mahendra Uttam Gaikwad ◽  
A. Krishnamoorthy ◽  
Vijaykumar S. Jatti
Keyword(s):  
Surface Integrity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Hardness Test ◽  
Machined Surface ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time

PurposeElectrical discharge machining (EDM) of hard materials like NiTi 60 alloys is important as it finds application in different sectors of engineering such as automobile, aircraft, biomedical, oil industries, etc.Design/methodology/approachThe first target of this investigation is to determine the effect of process parameters such as current, voltage, pulse on time and pulse off time on the material removal rate (MRR), surface roughness (SR) and white layer formation (WLT) for NiTi 60 smart material alloy. The secondary aim is to identify the presence of surface integrity parameters such as cracks, WLT, microvoids, globules and debris formation by using the scanning electron microscopy technique and with the use of ImageJ software for die sink EDM machining of NiTi 60 alloy.FindingsThe results reveal that current is significant for MRR, voltage and current influence SR, and for WLT, voltage is a significant factor. The experimentation study also shows the generation of oxide and carbide layers on the machined surface, which were evident with the use of the X-ray diffraction technique. The presence of these oxide and carbide layers causes to form WLT on the machined surface and thereby increases the hardness of the machined surface.Originality/valueHardness test was performed with Vickers hardness tester, which gives evidence for the increase in hardness of machined surface due to the generation of WLT.

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

scholarly journals Multi-Objective Optimization of Wire Electrical Discharge Machining of AL 2124/SIC Composite

2019 ◽  
Vol 9 (1) ◽  
pp. 2155-2163
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Strength ◽  
Wire Electrical Discharge Machining ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Predicted Values ◽  
Pulse On Time ◽  
Pulse Off Time

The growing demand for the use of high strength to weight alloys in industries for manufacturing complex structures challenges the machinability of such advanced materials. In the present investigation, the machinability of SiC particle reinforced Al 2124 composite was studied on Wire electrical discharge machining (WEDM). The process parameters namely pulse on-time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV) were optimized by utilizing the central composite design layout. The output responses such as kerf and material removal rate (MRR) were studied in detail. The single and multi-objective optimization was studied for a combination effect using Derringer’s desirability approach and Genetic Algorithm (GA). The experimental and predicted values for each response were validated at the optimized condition. The experimental results were found in line with the predicted values. Multi objective optimization of kerf and MRR by GA showing better result compared to RSM.

scholarly journals Experimental Study on the Influence of Machining Conditions on the Quality of Electrical Discharge Machined Surfaces of aluminum alloy Al5052

Machines ◽  
2020 ◽  
Vol 8 (1) ◽  
pp. 12 ◽  
Author(s):  
Angelos P. Markopoulos ◽  
Emmanouil-Lazaros Papazoglou ◽  
Panagiotis Karmiris-Obratański
Keyword(s):  
Aluminum Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Parameters ◽  
Machining Processes ◽  
Machining Conditions ◽  
Pulse On Time ◽  
Machined Surfaces

Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

scholarly journals MODELLING AND OPTIMIZATION OF PERFORMANCE CHARACTERISTICS IN ELECTRICAL DISCHARGE MACHINING ON TITANIUM ALLOY

2013 ◽  
Vol 43 (1) ◽  
pp. 33-40
Author(s):  
Md. Ashikur Rahman Khan
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Short Pulse ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Pulse Interval ◽  
Hard Material ◽  
Set Up ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) technique possesses noticeable advantages over othermachining process and can machine any hard material effectively. Proper selection of parameters in EDM isvery much essential to achieve better performance characteristics that are still challenging. This study attemptsto investigate the effects of parameters on EDM performance characteristics on Ti-6Al-4V utilizing coppertungsten as electrode and negative polarity of the electrode. Mathematical model associating the influences ofthese variables and the EDM characteristics such as material removal rate (MRR) and tool wear rate (TWR)are set up in this study. The optimal machining conditioning in favor of MRR and TWR are estimated. Design ofexperiments method and response surface methodology techniques are adopted to attain the objectives. Analysisof variance (ANOVA) has been performed for the validity test of the fit and adequacy of the proposed models.Optimum MRR is found at high discharge ampere, long pulse on time and short pulse off time. 8A peak current,10 ?s pulse on time and 184 ?s pulse interval yields lowest TWR. The result of this investigation guides torequired process outputs and economical industrial machining optimizing the input factors.DOI: http://dx.doi.org/10.3329/jme.v43i1.15778

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics

2019 ◽  
Vol 233 (14) ◽  
pp. 2515-2530 ◽  
Author(s):  
R Rajeswari ◽  
MS Shunmugam
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Machining Process ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Pulse On Time

Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a consequential reduction in cycle time. Powder mix and ultrasonic assistance are employed in the electrical discharge machining process to create gap conditions favoring material removal. In the present work, experiments are carried out on hardened D3 die steel using full-factorial design based on three levels of voltage, current and pulse on time. The gap phenomena in graphite powder-mixed and ultrasonic-assisted rough electrical discharge machining are studied using a detailed analysis of pulse shapes and their characteristic trains. Two new parameters, namely, energy expended over a second ( E) and performance factor ( PF) denoting the ratio of energy associated with sparks to total discharge energy, bring out gap conditions effectively. In comparison with the conventional electrical discharge machining for the selected condition, it is seen that the graphite powder mixed in the dielectric enhances the material removal rate by 20.8% with E of 215 J and PF of 0.227, while these values are 179.8 J and 0.076 for ultrasonic-assisted electrical discharge machining with marginal reduction of 3.9%. Cross-sectional images of workpieces also reveal the influence of electrical discharge machining conditions on the machined surface. The proposed approach can be extended to different powder mix and ultrasonic conditions to identify condition favoring higher material removal.

A DoE–TOPSIS method-based meta-model for parametric optimization of non-traditional machining processes

2019 ◽  
Vol 14 (2) ◽  
pp. 430-455 ◽  
Author(s):  
Shankar Chakraborty ◽  
Prasenjit Chatterjee ◽  
Partha Protim Das
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Topsis Method ◽  
Machining Performance ◽  
Machining Processes ◽  
Inconel 718 Alloy ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

PurposeTo meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional machining (NTM) processes have now become quite popular in manufacturing industries. To explore the fullest machining capability of these NTM processes, it is often required to operate them while setting their different controllable parameters at optimal levels. This paper aims to present a novel approach for selection of the optimal parametric mixes for different NTM processes in order to assist the concerned process engineers.Design/methodology/approachIn this paper, design of experiments (DoE) and technique for order preference by similarity to ideal solution (TOPSIS) are combined to develop the corresponding meta-models for identifying the optimal parametric combinations of two NTM processes, i.e. electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) processes with respect to the computed TOPSIS scores.FindingsFor EDM operation on Inconel 718 alloy, lower settings of open circuit voltage and pulse-on time and higher settings of peak current, duty factor and flushing pressure will simultaneously optimize all the six responses. On the other hand, for the WEDM process, the best machining performance can be expected to occur at a parametric combination of zinc-coated wire, lower settings of pulse-on time, wire feed rate and sensitivity and intermediate setting of pulse-off time.Practical implicationsAs the development of these meta-models is based on the analysis of the experimental data, they are expected to be more practical, being immune to the introduction of additional parameters in the analysis. It is also observed that the derived optimal parametric settings would provide better values of the considered responses as compared to those already determined by past researchers.Originality/valueThis DoE–TOPSIS method-based approach can be applied to varieties of NTM as well as conventional machining processes to determine the optimal parametric combinations for having their improved machining performance.

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