scholarly journals Study of the Effect of Machining Parameters on Material Removal Rate and Electrode Wear during Electric Discharge Machining of Mild Steel

2012 ◽  
pp. 213-219
Keyword(s):  
Mild Steel ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electric Discharge Machining

Nano Graphite Powder Assisted Electric Discharge Machining Characteristics of ZM21 Magnesium Alloy

2015 ◽  
Vol 787 ◽  
pp. 406-410
Author(s):  
S. Santosh ◽  
S. Javed Syed Ibrahim ◽  
P. Saravanamuthukumar ◽  
K. Rajkumar ◽  
K.L. Hari Krishna
Keyword(s):  
Magnesium Alloy ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Zm21 Magnesium Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Magnesium alloys are used in many applications, particularly in orthopaedic implants are very difficult to machine by conventional processes because of their complex 3D structure and limited slip system at room temperature. Hence there is an inherent need for alternative processes for machining such intricate profiles. Electric Discharge Machining is growing rapidly in tool rooms, die shops and even in general shop floors of modern industries to facilitate complex machining for difficult-to-machine materials and provide better surface integrity. Therefore, the use of electric discharge machining on ZM21 magnesium alloy is attempted in this paper. Nanographite powder is added for machining zone to enhance the electrical conductivity of EDM oil by way it improves the machining performance. Machining parameters such as the current, pulse on time and pulse off time were process parameters to explore their effects on the material removal rate and tool wear rate. It is observed that, an increased material removal rate was due to the enhanced electrical and thermal conductivity of the EDM oil.

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.

Electric discharge sawing of hybrid metal matrix composites

2015 ◽  
Vol 231 (10) ◽  
pp. 1775-1782 ◽  
Author(s):  
Ravinder Kumar ◽  
Inderdeep Singh
Keyword(s):  
Material Removal Rate ◽  
Electric Discharge ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Debris Accumulation ◽  
Carbon Particles ◽  
Hybrid Metal Matrix Composite ◽  
Sawing Process

Electric discharge sawing process is a novel process for the enrichment of capabilities of electric discharge machining. The process has been developed to cut materials at greater depths where the effect of flushing becomes ineffective. During electric discharge machining at greater depths, ineffective flushing prevents debris and carbon particles from leaving the machining zone and gets accumulated in the sparking zone reducing the spark efficiency. This reduces material removal rate and causes arcing or short circuiting which may damage the workpiece and/or tool surface. In the present experimental endeavor, a new process capable of preventing debris accumulation during machining of slots at large depth and subsequently increasing material removal rate has been developed. In the process, a reciprocating motion is given to the tool blade similar to the power hacksaw blade. An experimental investigation based on central composite design has been conducted on hybrid metal matrix composite to evaluate the effect of input parameters on material removal rate and tool wear rate. It has been found that the electric discharge sawing process is quick and effective as compared to the conventional cutting process.

scholarly journals Comparative Analysis of Machining Characteristics of EDM and ECM during Machining of Ti-6Al-4V

2021 ◽  
Vol 23 (2) ◽  
Author(s):  
Banwait S.S. ◽  
◽  
Sanjay S ◽  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Pulse On Time ◽  
Surface Finish Effect ◽  
Machining Characteristics

The present work explains the machining of Titanium alloy using Electric Discharge Machining & Electro-Chemical Machining. This work aims to analyze the role of Current, Pulse on Time, Voltage and hence optimize the Material Removal Rate and Surface Roughness in Electric Discharge Machining. In the same way, it also aims to analyze the role of Concentration, Feed, and Voltage and optimize the Material Removal Rate and Surface Roughness in Electro-Chemical Machining. The various approaches like Taguchi & Analysis of Variance are executed to study the performance characteristics of the input parameters on the output parameters. The whole work is followed by a validation test and hence confirming the obtained values. Thus, it reveals the acceptability of the model. The work tells that Material Removal Rate and Surface Finish effect is more in Electro-Chemical Machining as compared to Electric Discharge Machining. For Material Removal Rate, Current and Feed are more responsible parameters for Electric Discharge Machining. In the same way; electrolyte concentration and Feed are more responsible parameters for Electro-Chemical Machining respectively.

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