Electrical Discharge Machining of SiC and Gr Reinforced 6061-T6 Aluminum Alloy Hybrid Composite Fabricated by Friction Stir Processing

2013 ◽  
Author(s):  
Murahari Kolli ◽  
Devaraj Aruri ◽  
Kumar Adepu
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Machining Performance ◽  
Friction Stir

Aluminum based hybrid composites are advanced materials having the properties of high hardness, superior wear resistance, strength, high elevated temperature and low thermal expansion coefficient. These hybrid composites are widely used in industries like automobile and aerospace. In this present paper 6061-T6 Aluminum alloy reinforced with SiC and Gr particles, hybrid composites are fabricated by using Friction stir processing (FSP) technique. It prevents the further development of hybrid composites for machining by nonconventional methods like water jet and laser cutting process. Electrical discharge machining (EDM) is used for machining the complex shapes of the material. This paper presents an overview of EDM studies conducted on the Al-SiC/Gr hybrid composites using a copper electrode in EDM. The EDM experiment machining parameters such as the dielectric fluid, peak current, pulse on, pulse off times are changed to explore their effects on machining performance, material removal rate (MRR), Tool wear rate (TWR), and surface roughness (SR). It is observed that the MRR and SR of the Al-SiC/Gr hybrid composites increase with an increase in the current.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

An intelligent approach to optimize the electrical discharge machining of titanium alloy by simple optimization algorithm

2020 ◽  
pp. 095440892096468
Author(s):  
Anshuman Kumar Sahu ◽  
Joji Thomas ◽  
Siba Sankar Mahapatra
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimal Solution ◽  
Machining Parameters ◽  
Machining Performance ◽  
Intelligent Approach ◽  
Pulse On Time

Electrical discharge machining (EDM) is a thermo-electrical process that can be conveniently utilized for generating complex shaped profiles on hard-to-machine conductive materials using metallic tool electrodes. In this work, composite tools made of copper-tungsten-boron carbide (Cu-W-B4C) manufactured by powder metallurgy (PM) route are used during machining of titanium alloy (Ti6Al4V). The effect of four input machining parameters viz. current, pulse-on-time, duty cycle and percentage of tungsten and boron carbide on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) is studied. A novel meta-heuristic approach such as simple optimization (SOPT) algorithm has been used for single and multi-objective optimization. The pareto-optimal solutions obtained by SOPT have been ranked by VIKOR method to find out the best suitable optimal solution. Analysis of experimental data suggests vital information for controlling the machining parameters to improve the machining performance.

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.

Effects of Electrical Discharge Energy on Machining Performance of Sintered NdFeB Magnet

2009 ◽  
Vol 620-622 ◽  
pp. 711-714 ◽  
Author(s):  
Li Li ◽  
Guang Ming Yuan ◽  
Zong Wei Niu ◽  
Rong Guo Hou
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Discharge Energy ◽  
Machining Performance ◽  
Ndfeb Magnet ◽  
Machined Surface ◽  
Micro Cracks ◽  
Ndfeb Permanent Magnet

Sintered NdFeB permanent magnet is widely used in many areas because of its excellent magnet property. In this study, the machining parameters of electrical discharge machining (EDM) are varied to study the effects of electrical discharge energy on material removal rate and surface roughness of NdFeB magnet. Moreover, the micro-cracks on the machined surface induced by EDM are also examined. The experimental results reveal that the MRR increases with the electrical discharge energy. The number of surface cracks on the machined surface increases with the enhancement of discharge energy Thus, using EDM process to machine sintered NdFeB magnet depends on setting the machining parameters to prevent surface crack.

Investigation on the Effect of Multi Wall Carbon Nano Tubes in Wire Electrical Discharge Machining of Hybrid Metal Matrix Composites

2014 ◽  
Vol 592-594 ◽  
pp. 456-460
Author(s):  
S. Ramesh ◽  
N. Natarajan ◽  
Vijayan Krishnaraj ◽  
K. Sathish Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Matrix Composites ◽  
Machining Performance ◽  
Carbon Nano Tubes

Wire Electrical Discharge Machining (WEDM) is an very accurate non-traditional machining process for producing parts with accurate dimensions and complex shapes. The performance of WEDM is measured by evaluating the parameters like Material Removal Rate (MRR), Surface Roughness (Ra), cracks, voids, pores and recast layer. In this paper, an attempt is made to improve the machining performance by adding multi wall carbon nanotube (MWCNT) with dielectric fluid. The MRR, Ra and surface characteristics are compared with surface that is machined using dielectric fluid with and without MWCNT. The results show that addition of MWCNT improves the MRR and surface finish.

Turning by electrical discharge machining: A review

2016 ◽  
Vol 231 (2) ◽  
pp. 195-208 ◽  
Author(s):  
Vikas Gohil ◽  
YM Puri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Free Form ◽  
Machining Parameters ◽  
Machining Performance ◽  
Complex Shapes ◽  
Discharge Machine ◽  
Future Direction

Turning by electrical discharge machining is an emerging area of research. Generally, wire-cut electrical discharge machining is used for turning because it is not concerned with electrode tooling cost. The process variant die-sinking electrical discharge machining can also be effectively used to generate free-form cylindrical geometries on difficult-to-cut materials with complex shapes at both macro and micro levels. The machining performance of electric discharge machine is defined and influenced by its process parameters, which significantly affects production rate and the quality of machined component. Thus, it is very important to select machining parameters and their levels cautiously in order to improve the outcome of the process. In this article, the authors have reviewed the research work carried out in the area of electrical discharge turning in the last decade for the improvement of material removal rate, surface integrity and roundness. In this review, various techniques reported by electrical discharge machining researchers on turning have been categorised in different electrical discharge machining variants. The article also discussed the future direction of research work in the same area.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

scholarly journals A study on Electrical Discharge Machining of Titanium Grade2 with experimental and theoretical analysis

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Emmanouil L. Papazoglou ◽  
Panagiotis Karmiris-Obratański ◽  
Beata Leszczyńska-Madej ◽  
Angelos P. Markopoulos
Keyword(s):  
Power Distribution ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Process ◽  
Heat Transfer Analysis ◽  
Machining Parameters ◽  
Machining Performance ◽  
Plasma Flushing Efficiency

AbstractTitanium alloys, due to their unique properties, are utilized in numerous modern high-end applications. Electrical Discharge Machining (EDM) is a non-conventional machining process, commonly used in machining of hard-to-cut materials. The current paper, presents an experimental study regarding the machining of Titanium Grade2 with EDM, coupled with the development of a simulation model. The machining performance indexes of Material Removal Rate, Tool Wear Ratio, and Average White Layer Thickness were measured and calculated for different pulse-on currents and pulse-on times. Moreover, the developed model that integrates a heat transfer analysis with deformed geometry, allows to estimate the power distribution between the electrode and the workpiece, as well as the Plasma Flushing Efficiency, giving an insight view of the process. Finally, by employing the Response Surface Methodology, educed regression models that correlate the machining parameters with the corresponding results, while for all the aforementioned indexes, ANOVA was performed.

An integrated evolutionary approach for modelling and optimization of wire electrical discharge machining

2011 ◽  
Vol 225 (4) ◽  
pp. 549-567
Author(s):  
D Kondayya ◽  
A Gopala Krishna
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Evolutionary Approach ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Wedm Process ◽  
Modelling And Optimization

This paper presents an application of an integrated evolutionary approach for modelling and optimization of a wire electrical discharge machining (WEDM) process. The proposed methodology consists of two parts. In the first part, a novel application of genetic programming (GP) is proposed. GP is an evolutionary modelling algorithm which uses principles similar to genetic algorithms to model highly non-linear and complex processes, resulting in accurate and reliable models. Two important aspects of machining performance of WEDM, namely metal removal rate and surface roughness, are modelled based on experimental data using GP in terms of four prominent input variables. The effect of machining parameters on the performance measures is also reported. In the second part, as the chosen machining performances are opposite in nature, the problem under consideration is formulated as a multi-objective optimization problem and solved using an efficient evolutionary optimization algorithm, non-dominated sorting genetic algorithm-II (NSGA-II). The outcome of Pareto optimal solutions is presented. The work presents a fully fledged evolutionary approach for optimization of the process.

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.

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