A review of machining parameters that effect to wire electrode wear

2017 ◽  
Author(s):  
Paphakom Pitayachaval ◽  
Phongchai Jittamai ◽  
Thanakham Baothong
Keyword(s):  
Electrode Wear ◽  
Machining Parameters ◽  
Wire Electrode

scholarly journals Influence of Energy Parameters of Micro WEDM on Kerf

2012 ◽  
Vol 576 ◽  
pp. 527-530
Author(s):  
Mohammad Yeakub Ali ◽  
W.Y.H. Liew ◽  
S.A. Gure ◽  
B. Asfana
Keyword(s):  
Experimental Data ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Wire Electrode ◽  
Wire Vibration ◽  
The Wire ◽  
Micro Wedm

This paper presents the estimation of kerf width in micro wire electrical discharge machining (micro WEDM) in terms of machining parameters of capacitance and gap voltage. An empirical model is developed by the analysis of variance (ANOVA) of experimental data. Using a wire electrode of 70 µm diameter, a minimum kerf width is found to be 92 µm for the micro WEDM parameters of 0.01 µF capacitance and 90.25 V gap voltage. Around 30% increament of the kerf is found to be high. The analysis also revealed that the capacitance is more influential parameter than gap voltage on kerf width produced by micro WEDM. As the gap voltage determines the breakdown distance and affects the wire vibration, the wire vibration factor is to be considered in the analysis and in formulation of model in future study.

Machining Characteristics of EDM for Non-Conductive Ceramics Using Adherent Copper Foils

2010 ◽  
Vol 154-155 ◽  
pp. 794-805 ◽  
Author(s):  
Yao Jang Lin ◽  
Yan Cherng Lin ◽  
A Cheng Wang ◽  
Der An Wang ◽  
Han Ming Chow
Keyword(s):  
Removal Rate ◽  
Pyrolytic Carbon ◽  
Industrial Applications ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machined Surface ◽  
Conductive Material ◽  
Conductive Ceramics ◽  
The Stability

This study investigates the feasibility of EDM for processing ZrO2 and Al2O3 of non-conductive ceramics, which were covered by an assisted conductive material, an adherent copper foil, on the workpiece surface. The conductive material adhered on the surface of the non-conductive ceramics would induce a series of electrical discharges between the tool electrode and the workpiece in the initial stage of the EDM process. Thus, the pyrolytic carbon that cracked from kerosene was formed and deposited on the machined surface to maintain the progress of EDM. In this work, the essential EDM machining parameters were varied to determine the effects on material removal rate (MRR), electrode wear rate (EWR), and surface roughness. The stability of EDM progress and the surface integrities of ZrO2 and Al2O3 machined by EDM were also investigated. The aim of this study is to explore the feasibility and development of an applicable process for processing non-conductive ceramics through EDM. Moreover, the exploitation of this work can be applied to industrial applications and used to develop machining techniques for non-conductive ceramics.

Multi-Objective Optimization of Electrical Discharge Machining Parameters for 2024 Aluminum Alloy Using Grey-Taguchi Method

2020 ◽  
Vol 998 ◽  
pp. 55-60
Author(s):  
Jurapun Phimoolchat ◽  
Apiwat Muttamara
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
2024 Aluminum Alloy ◽  
Multi Objective ◽  
Effect Estimation ◽  
Voltage Performance ◽  
Pulse On Time

This paper focused on Grey relational analysis (GRA) to optimize EDM parameters through multi-objective optimization for Al2024 aluminum and electrode graphite ISO-63 was used as a cutting tool. The process parameters pulse on time, duty factor, pulse current and open voltage. Performance characteristics examined included material removal rate (MRR), electrode wear ratio (EWR) and surface roughness (SR). Taguchi’s 27 experimental designs, often called an orthogonal array (OA), was utilized to ignore interaction and concentrate on main effect estimation. GRA was performed to optimize input parameters levels. Results were that MRR increased from 35.00 to 35.11 mm3/min, EWR decreased from 11.63 to 10.89 mm3/min, and SR decreased from 5.01 to 4.97 μm. Taguchi and GRA resulted in clear improvements in MRR, EWR, and SR.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

Optimization of EDM Hole Drilling Parameters in Machining of MoSi2-SiC Intermetallic/Composites for Improving Geometrical Tolerances

2015 ◽  
Vol 14 (04) ◽  
pp. 259-272 ◽  
Author(s):  
L. Selvarajan ◽  
C. Sathiya Narayanan ◽  
R. Jeyapaul
Keyword(s):  
Ceramic Composites ◽  
Performance Characteristics ◽  
Drilling Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
New Approach ◽  
Drilling Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing

Intermetallic/ceramic composites with multiple responses are based on L18 orthogonal array with gray relational analysis (GRA). This paper presents a new approach for the optimization of drilling parameters on drilling MoSi 2– SiC composites. Optimal machining parameters can then be determined by the gray relational grade as the performance index. In this study, the sparking parameters namely current (I), pulse on time (t on ), pulse off time (t off ), spark gap and dielectric flushing pressure (P) are optimized with considerations of multiple performance characteristics including multi responses such as material removal rate (MRR), electrode wear rate (EWR), circularity (CIR), cylindricity (CYL), perpendicularity (PER). A gray relational grade obtained from the GRA is used to solve the electrical discharge machining (EDM) process with the multiple performance characteristics. Based on the gray relational grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by ANOVA. Confirmation test is conducted to validate the test result. Experimental results have shown that the responses in EDM drilling process can be improved effectively through the new approach.

scholarly journals Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1647
Author(s):  
Yue-Peng Zeng ◽  
Chiang-Lung Lin ◽  
Hong-Mei Dai ◽  
Yan-Cherng Lin ◽  
Jung-Chou Hung
Keyword(s):  
Process Parameters ◽  
Performance Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Technique ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relative Closeness ◽  
Machining Parameter

The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

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,

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.

Optimization of Multiple Performances for EDM in Gas Media Using Grey Relational Analysis

2014 ◽  
Vol 620 ◽  
pp. 173-178
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Grey Relational Analysis ◽  
Electrical Discharge Machining ◽  
Design Method ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relational Analysis ◽  
Grey Relational ◽  
Machining Parameter

The aim of this investigation is to optimize the multiple performance characteristics of electrical discharge machining (EDM) for SKD 61 tool steel in gas media using grey relational analysis. The three most important machining characteristics namely material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR) were considered as the measures of the performance characteristics. A series of experiments were conducted according to an L18 orthogonal array based on the Taguchi experimental design method. The observed data obtained from the experiments were evaluated to determine the optimization of machining parameters correlated with multiple performance characteristics through grey relational analysis. Moreover, analysis of variance (ANOVA) was conducted to explore the significant machining parameters crucially affecting the multiple performance characteristics. In addition, the optimal combination levels of machining parameters were also determined from the response graph of grey relational grades for each level of machining parameter.

Sign in / Sign up

Export Citation Format

Share Document