Simulation and experimental investigation of tool wear rate in dry and near-dry EDM process

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Vaibhav Sidraya Ganachari ◽  
Uday Chate ◽  
Laxman Waghmode ◽  
Prashant Jadhav ◽  
Satish Mullya
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Spring Steel ◽  
Experimental Results ◽  
Electrical Model ◽  
Tool Wear Rate ◽  
Content Type ◽  
Dry Edm ◽  
Steel Material

Purpose Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM). Design/methodology/approach This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining. Findings It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM. Originality/value The range of predicted results and the experimental results are in close agreement, authenticating the model.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

Modeling the tool wear rate in powder mixed electro-discharge machining of titanium alloys using dimensional analysis of cryogenically treated electrodes and workpiece

2016 ◽  
Vol 231 (2) ◽  
pp. 271-282 ◽  
Author(s):  
Sanjeev Kumar ◽  
Rupinder Singh ◽  
Ajay Batish ◽  
TP Singh
Keyword(s):  
Mathematical Model ◽  
Wear Rate ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Dimensional Analysis ◽  
Electric Discharge ◽  
Cryogenic Treatment ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
X Ray

Three grades of titanium alloy TITAN 15, TITAN 21, and TITAN 31 were machined using powder mixed electric discharge machining to study the effect of cryogenic treatment and its effect on tool wear rate (TWR). Thereafter, an attempt has been made to develop a mathematical model for predicting TWR using dimensional analysis using the outcome of the Taguchi model and thermo-physical properties of tool materials. The model shows the significant role of thermal conductivity on TWR in electric discharge machining of titanium alloys. The predicted values from the developed mathematical model were validated and were found to be in good agreement with the experimental results. Microscopic investigations on selected tool samples were performed using scanning electron microscope, energy-dispersive X-ray spectrometer, and X-ray diffraction. The results showed transfer of material on the tool surface from the workpiece, dielectric, and the powder.

scholarly journals Optimization of Machining Variables in Electric Discharge Machining Using Stainless Steel 317 in Full Factorial Method

2020 ◽  
Vol 22 (1) ◽  
pp. 105-118 ◽  
Author(s):  
S. Nandhakumar ◽  
S. Sathish Kumar ◽  
K. Sakthivelu
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Machining Time ◽  
Input Variables

AbstractElectric Discharge Machining (EDM) is a non-conventional machining process and has a larger extent of application in manufacturing industry due to its accuracy. EDM simply uses electrical spark between the tool and workpiece in presence of dielectric medium to erode the workpiece in controlled manner. Improving the material removal rate and decreasing the tool wear rate (TWR), achieving higher surface finish, reducing machining time and enhancing dimensional accuracy are the major areas of focus in electrical discharge machining (EDM) process of SS 317 grade steel. In this research work effort to reduce the tool wear rate is concentrated by comparing the machining performance of two distinct electrodes namely copper and brass. Each electrode has their unique machining capabilities and the experimental results were compared in-terms of tool wear rate (TWR), Metal Removal Rate (MRR) and Machining Time (TM). Input variables were optimized based on the experimental output responses to achieve optimal level of input variables.

scholarly journals Effect of deep cryogenic treatment on copper electrode for non-traditional electric discharge machining (EDM)

2019 ◽  
Vol 10 (2) ◽  
pp. 413-427
Author(s):  
Gurdev Singh Grewal ◽  
Dhiraj Parkash Dhiman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Copper Electrode ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Electrode Rotation ◽  
Input Parameters

Abstract. In the last few decades, non-traditional machining made the machining process easier than the traditional machining method. Electric discharge machining (EDM) is one of the most prominent methods of non-traditional machining processes. By the use of EDM, a complex profile and high hardness materials can be easily machined, which cannot easily be machined by the traditional machining method. EDM is widely used by the industries. This paper investigates an experiment with the cryogenically treated copper electrode and an ordinary copper electrode with various input parameters like the electrode rotation, gap voltage and discharge current for an EN24 (a high-strength and wear-resistant steel) material. An experiment was performed with electric discharge machining. Designs of an experiment are carried out using the Taguchi approach. An orthogonal L16 array prepared and used the different combination of the three input parameters (current, electrode rotation and gap voltage) to find an optimum value of the factors. The output factors are the overcut (OC), the tool wear rate (TWR) and surface roughness (Ra). The optimal level and importance levels of each of these parameters are obtained statically using an analysis-of-variance (ANOVA) table through the analysis of the S∕N ratio. The study also compares the theoretical and experimental values of the overcut, tool wear rate and surface roughness for traditional and non-traditional EDM. The following research finds optimal or dominating factors (current and rotational speed) for the TWR and Ra in both traditional and non-traditional electric discharge machining; moreover there was a reduction of approximately 9 % in overcut, 13.25 % in the tool wear rate and 15.75 % in surface roughness for the deep cryogenic and non-traditional machining process.

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