Optimization of Machining Parameters for Surface Roughness in EDM of AISI 1045 Based on Taguchi Technique

2010 ◽  
Author(s):  
Subodh Kumar ◽  
Sanjay Agarwal
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge Machining ◽  
Experimental Studies ◽  
Performance Measure ◽  
Influential Factors ◽  
Machining Parameters ◽  
Aisi 1045 ◽  
Experimental Findings ◽  
Good Agreement

Electrical discharge machining (EDM) is a nontraditional manufacturing technique that has been widely used in the production of tools and dies throughout the world in recent years. The most important performance measure in EDM is the surface roughness. In this study, the effect and optimization of machining parameters on surface roughness in an EDM operation was investigated by using the Taguchi method. The experimental studies were conducted under varying discharge current, duty cycle and pulse-duration. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) were employed to the study the surface roughness in the EDM of AISI 1045 tool steel. It was observed that the discharge current was the most influential factors on the surface roughness. To validate the study, confirmation experiment has been carried out at optimum set of parameters and predicted results have been found to be in good agreement with experimental findings.

Effect of Machining Parameters on Surface Roughness in µ-EDM of Conductive SiC

2014 ◽  
Author(s):  
Krishna Kumar Saxena ◽  
Sanjay Agarwal ◽  
Jyoti Mukhopadhyay
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Goodness Of Fit ◽  
Electrical Discharge Machining ◽  
Experimental Studies ◽  
Performance Measure ◽  
Machining Parameters ◽  
Chi Square ◽  
Precision Engineering ◽  
Micro Electrical Discharge Machining

Micro-electrical discharge machining (μ-EDM) is a non-traditional manufacturing technique that has been widely used in the production of precision engineering components throughout the world in recent years. The most important performance measure in μ-EDM is the surface roughness. The Silicon Carbide is a reaction bonded advanced ceramic that is the fourth hardest material after Diamond, boron nitride and boron carbide. Due to low fracture toughness, machining of Silicon Carbide is accomplished with EDM. In this study, the experimental studies were conducted under varying gap voltage, capacitance and threshold. The numbers of experiments were reduced by L9 array of Taguchi’s theory of DOE. Signal-to-noise (S/N) ratio was employed to determine the most influencing levels of parameters that affect the surface roughness in the μ-EDM of conductive silicon carbide. To validate the study, confirmation experiment has been carried out at optimum set of parameters and predicted results have been found to be in good agreement with experimental findings. A fuzzy logic model for predicting surface roughness during μEDM was also developed on MATLAB software and the goodness of fit of predicted values with experimental values was tested using chi-square test.

scholarly journals Analysis, predictive modelling and multi-response optimization in electrical discharge machining of Al-22%SiC metal matrix composite for minimization of surface roughness and hole overcut

2020 ◽  
Vol 7 ◽  
pp. 20 ◽  
Author(s):  
Subhashree Naik ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Discharge Current ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Response Optimization ◽  
Pulse On Time

Due to the widespread engineering applications of metal matrix composites especially in automotive, aerospace, military, and electricity industries; the achievement of desired shape and contour of the machined end product with intricate geometry and dimensions that are very challenging task. This experimental investigation deals with electrical discharge machining of newly engineered metal matrix composite of aluminum reinforced with 22 wt.% of silicon carbide particles (Al-22%SiC MMC) using a brass electrode to analyze the machined part quality concerning surface roughness and overcut. Forty-six sets of experimental trials are conducted by considering five machining parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken's design of experiments (BBDOEs). This article demonstrates the methodology for predictive modeling and multi-response optimization of machining accuracy and surface quality to enhance the hole quality in Al-SiC based MMC, employing response surface methodology (RSM) and desirability function approach (DFA). Finally, a novel approach has been proposed for economic analysis which estimated the total machining cost per part of rupees 211.08 during EDM of Al-SiC MMC under optimum machining conditions. Thereafter, under the influence of discharge current several observations are performed on machined surface morphology and hole characteristics by scanning electron microscope to establish the process. The result shows that discharge current has the significant contribution (38.16% for Ra, 37.12% in case of OC) in degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The machining data generated for the Al-SiC MMC will be useful for the industry.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

scholarly journals Multi-Response Optimization of Electrical Discharge Machining Using the Desirability Function

Micromachines ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 72 ◽  
Author(s):  
Rafał Świercz ◽  
Dorota Oniszczuk-Świercz ◽  
Tomasz Chmielewski
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Desirability Function ◽  
Statistical Significance ◽  
Time Interval ◽  
Machining Parameters ◽  
Response Optimization

Electrical discharge machining (EDM) is a modern technology that is widely used in the production of difficult to cut conductive materials. The basic problem of EDM is the stochastic nature of electrical discharges. The optimal selection of machining parameters to achieve micron surface roughness and the recast layer with the maximal possible value of the material removal rate (MRR) is quite challenging. In this paper, we performed an analytical and experimental investigation of the influence of the EDM parameters: Surface integrity and MRR. Response surface methodology (RSM) was used to build empirical models on the influence of the discharge current I, pulse time ton, and the time interval toff, on the surface roughness (Sa), the thickness of the white layer (WL), and the MRR, during the machining of tool steel 55NiCrMoV7. The surface and subsurface integrity were evaluated using an optical microscope and a scanning profilometer. Analysis of variance (ANOVA) was used to establish the statistical significance parameters. The calculated contribution indicated that the discharge current had the most influence (over the 50%) on the Sa, WL, and MRR, followed by the discharge time. The multi-response optimization was carried out using the desirability function for the three cases of EDM: Finishing, semi-finishing, and roughing. The confirmation test showed that maximal errors between the predicted and the obtained values did not exceed 6%.

scholarly journals Optimisation of Cutting Parameters for Minimal Surface Roughness in Single Point Diamond Turning of TI6AL4VELI

2019 ◽  
Vol 8 (12) ◽  
pp. 3222-3226
Keyword(s):  
Surface Roughness ◽  
Minimal Surface ◽  
Feed Rate ◽  
Single Point ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Influential Factors ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Diamond Cutting Tool

In this study the effect and optimisation of machining parameters on surface roughness in a facing operation of Ti6Al4VELI by single point diamond machining have been investigated. The experimental studies carried under varying cutting speeds, feed rates, different tool nose radius and depths of cut. The orthogonal array, signal-to-noise ratio (S / N) and variance analysis (ANOVA) were used to examine the performance characteristics of the Ti6Al4VELI alloy turning by using single-point diamond cutting tool. The influential factors on the surface roughness after machining are feed rate and cutting speed after the conclusions revealed. Whereas the feed rate had the most significant effect on tool life. Minimal surface roughness achieved after machining is in nano-level which is better than other conventional precision machining.

scholarly journals Findings of performance evaluation of EDM for different materials of electrodes and work pieces- a review

2018 ◽  
Vol 7 (4.5) ◽  
pp. 542
Author(s):  
Harshalkumar R. Mundane ◽  
Dr. A. V. Kale ◽  
Dr. J. P. Giri
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Performance Measure ◽  
Machining Process ◽  
Machining Parameters ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

EDM (Spark erosion) is non-conventional machining process which uses as removing unwanted material by electrical spark erosion. EDM Machining parameters affecting to the performance and the industries goal is to produce high quality of product with less time consuming and cost. To achieve these goals, optimizing the machining parameters such as pulse on time, pulse off time, cutting speed, depth of cut, duty cycle, arc gap, voltage etc. The performance measure of EDM is calculated on the basis of Material Remove Rate(MRR), Tool Wear Rate(TWR), and Surface Roughness(SR).The main objective of present work is to investigate of the influence of input EDM (Electro Discharge Machining) parameters on machining characteristics like surface roughness and the effects of various EDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, on different process response parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), tool wear ratio(TWR)and surface integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness (SR) and work piece material have been discussed.   

scholarly journals Parametric optimization of wire cut electrical discharge machining

2014 ◽  
Vol 3 (2) ◽  
pp. 212
Author(s):  
M. Durairaj ◽  
A.K.S. Ansari ◽  
M. H. Gauthamkumar
Keyword(s):  
Surface Roughness ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Fluid Pressure ◽  
Performance Criteria ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

Influence of Machining Parameters on Surface Roughness in WEDM Titanium Alloy

2013 ◽  
Vol 701 ◽  
pp. 349-353 ◽  
Author(s):  
J.B. Saedon ◽  
Paul J.R. Ding J.R. ◽  
M.S.M. Shawal ◽  
H. Husain ◽  
M.S. Meon
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Feed Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Thermo Electric ◽  
Peak Current ◽  
Wire Tension

Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy .This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.25mm.The objective of this work is to study the influence of three machining parameters namely peak current (IP), feed rate (FC) and wire tension (WT) to material removal rate and surface roughness followed by suggesting the best operating parameters towards good surface finish. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors and their interactions. Peak current was shown to have the greatest effect on surface roughness (33% PCR).

scholarly journals Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

2021 ◽  
Author(s):  
Antonio J. Sánchez Egea ◽  
Vitaliy Martynenko ◽  
Alejando Simoncelli ◽  
Gil Serrancoli ◽  
Daniel Martínez Krahmer
Keyword(s):  
Surface Roughness ◽  
Surface Properties ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Initial Surface ◽  
Friction Coefficients ◽  
Surface Conditions ◽  
Aisi 1045

AbstractForging dies are crucial in forging to manufacture accurate workpieces. These dies are generally made of AISI H steel series and hardened and tempered medium carbon alloy steel. Dies are processed by using high-speed milling + polishing or electrical discharge machining + polishing. The surface quality of the workpiece depends on the surface properties of these dies, where surface roughness, material hardness, and wear evolution of their surfaces are critical aspects to consider. This research analyzes different wire electrical discharge machining surface conditions combined with polishing treatment to describe their influence on friction and wear. Wire electrical discharge machining defines the disks’ surface properties in finishing and roughing conditions, and polishing treatment varies in time and paper sand depending on the roughness. Abbott-Firestone curves and Rsk-Rku roughness parameters characterize the surface roughness of each studied configuration. Room temperature pin-on-disk tests were performed to analyze friction coefficients and wear rate for AISI 1045 pins and AISI H13 disks. On average, the highest (0.284) and the lowest (0.201) friction coefficients were found for the combination of finishing wire electrical discharge machining + polishing and roughing wire electrical discharge machining conditions, respectively. Scanning electron microscope images were taken to describe the wear tracks and pin degradation for different sliding abrasive configurations. The diagram correlating the surface morphology and the friction coefficient predicts the wear damage on initial surface conditions, which is crucial in the forging industry to determine tool maintenance or replacement.

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