Modeling and Analysis on the Influence of Reinforcement Particle Size During EDM of Aluminum (Al/3.25Cu/8.5Si)/Fly Ash Composites

2016 ◽  
Vol 15 (04) ◽  
pp. 189-207 ◽  
Author(s):  
K. Ravi Kumar ◽  
V. S. Sreebalaji
Keyword(s):  
Aluminum Alloy ◽  
Fly Ash ◽  
Removal Rate ◽  
Stir Casting ◽  
Reinforcement Particle ◽  
Peak Current ◽  
Casting Technique ◽  
Software Analysis ◽  
Pulse On Time ◽  
Pulse Off Time

In the present study, aluminum alloy (Al/3.25Cu/8.5Si) composites reinforced with fly ash particles was fabricated using stir casting technique. Fly ash particles of three different size ranges 53–75, 75–103 and 103–125[Formula: see text][Formula: see text]m of 3, 6 and 9 weight percentages was reinforced in aluminum alloy. The effect of peak current, pulse on time, and pulse off time on surface roughness (SR), material removal rate (MRR) and tool wear rate (TWR) of electric discharge machining (EDM) was investigated. A central composite design using response surface methodology (RSM) was selected for conducting experiments, and mathematical models were developed using Design Expert V7.0.0 software. Analysis of variance (ANOVA) technique was used to check the significance of the models developed. Peak current was the major factor influencing the EDM of aluminum fly ash composites. The MRR, TWR, and SR of aluminum fly ash composites were also influenced by the size of the fly ash particles.

scholarly journals A Study On Machining Characteristics of Al7075-NiCr-Gr Metal Matrix Composites Through Wire – Cut Electro Discharge Machining

2021 ◽  
Author(s):  
R. Palani ◽  
M. Sakthivel ◽  
V. Chithambaram ◽  
Geetha Palani
Keyword(s):  
Removal Rate ◽  
Energy Dispersive Spectrometer ◽  
Stir Casting ◽  
Vital Role ◽  
Matrix Composites ◽  
Practical Applications ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Abstract The aluminium and its alloys play a vital role in industry for their wide practical applications. In the present work, Al7075 was reinforced with Ni-Cr and graphite by Stir casting method. Further the optimization of the machined composite was done by Taguchi method. It was inferred that the MRR value of 0.056435 g/min was obtained with input parameters of 8 amps current, 52 Volt, 4 µs pulse on time, 17 µs pulse off time by machining with WEDM and SR value of 3.3 µm showing smooth surface. The material removal rate of the composite was found and the morphology of the material was analysed by SEM with associated elemental analysis by energy dispersive spectrometer (EDS). The reinforcements present in the composite were also verified. The outcome of this micro structural investigation revealed that a non-uniform distribution of graphite particles takes place at all weight percentages of graphite reinforcement.

Performance Evaluation of Electrical Discharge Machining Die Sinking on Stainless Steel 316L Using Copper Impregnated Graphite

2014 ◽  
Vol 660 ◽  
pp. 48-54 ◽  
Author(s):  
Wahaizad Safiei ◽  
Safian Sharif ◽  
Ahmad Fairuz Mansor ◽  
Mohd Halimudin Mohd Isa
Keyword(s):  
Stainless Steel ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Time Range ◽  
Electrode Wear ◽  
Stainless Steel 316L ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This study presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of Electrical Discharge Machining (EDM) input parameters on characteristics of EDM process. The machining parameters include peak current, servo voltage, pulse ON time and pulse OFF time. The study was conducted using 2 levels of Full Factorial Method in Design of Experiments. The design expert software employed to perform all the data analysis for Full Factorial and Central Composite Design (CCD) experiments. This study evaluates the machining performance of the Stainless Steel 316L using Sodick EDM linear motor series AM3L which employed Copper impregnated graphite diameter 7.0 mm as the tool electrode. The response variables are material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR) and dimensional accuracy. The result shows that the peak current was the most significant factors to all variable responses. The servo voltage does not have significant effects to the machining responses in RSM. Higher current produced higher MRR, EWR, SR and Dimensional Accuracy. Maximum MRR was obtained at peak current range from 27amp to 38amp, pulse on time range from 120μs to 145μs and 60μs of pulse off time. Maximum EWR was obtained at peak current range from 27amp to 37amp, pulse on time range from 140μs to 160μs and 60μs of pulse off time. High probably, the minimum EWR only can be obtained if peak current parameter sets greater than 45amp. Lower dimensional accuracy and SR obtain at 5amp of pulse on time. Higher pulse off time produced lower MRR and EWR.Keywords: EDM Die sinking, Stainless Steel 316L, Copper Impregnated Graphite Electrode, Response Surface Methodology, Surface Roughness, Material Removal Rate, Electrode Wear Rate, Dimensional Accuracy

scholarly journals MRR - Performance on EDM Drilling over Nano Composite Material

2019 ◽  
Vol 8 (4) ◽  
pp. 12340-12345
Keyword(s):  
Composite Material ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Performance Measure ◽  
Peak Current ◽  
Multi Wall Carbon Nanotubes ◽  
Main Effect ◽  
Pulse On Time ◽  
Pulse Off Time

Now a day’s more research works are going on performance of MRR on various operations with respect to EDM machining. This research paper is to focus the same on parameters base with Performance measure of Material Removal Rate (MRR) in composite Material (Aluminum, Boron Carbide and Multi Wall Carbon NanoTubes (MWCNT) .The machine used for this research is Sink EDM with drilling operation. .Lots of statistical techniques are available to predict the accurate and reliable result form the research data. Here the Minitab 16 software is used to analyze the MRR performance. The input parameters selected for the EDM machine are: Pulse on time, pulse off time and voltage. The results were compared with the DOE-Taguchi approach (L9) Orthogonal array - result. [1] .Material Removal Rate was studied along with S/N ratio of Main effect plot, Means and Interaction Plot.[2] From software the main effect plots, residual plots, S/N ratio interaction plots and means was obtained The rapid increase with pulse on for MRR is resulted due to addition of nano powder and linearly increase with peak current. The optimal parameters combination was determined as CNT (1%), Pulse on (10 µs), Pulse off (2.5 µs) and Peak Current (50A) i.e. 1 4 4 2. The experimental results were checked with predicted results and a positive agreement was found. Comparing old studies the optimization values found by this experiment results with more MRR.

scholarly journals Experimental Investigation of Edm Die Sinking Process Parameters on Aluminium Alloy 5083 Using Design of Experiment

2017 ◽  
Vol 4 (1) ◽  
pp. 138-144
Author(s):  
Wahaizad Safiei ◽  
Muhamad Ridzuan Radin Muhamad Amin
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Design Of Experiment ◽  
Material Removal ◽  
Removal Rate ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time

In this paper, the results of surface roughness (Ra) and material removal rate (MRR) are presented based on experimental studies of Electrical Discharge Machining (EDM) process parameters. Pulse ON time, pulse OFF time, peak current, gap voltage and jump speed are the selected input parameters and the experiments were conducted with Aluminium Alloy 5083 as a workpiece, copper as an electrode and the response variables are surface roughness (Ra) and material removal rate (MRR). Design of Experiment and Analysis of Variance (ANOVA) were applied to identify the optimum settings.The result shows that the significant factors for the value of surface roughness (Ra) and material removal rate (MRR) are pulses ON time and peak current.

Influence Of Al203 Particle Mixed Dielectric Fluid on Machining Performance of Ti6Al4V

2021 ◽  
Author(s):  
Ranjith R ◽  
Manoj Prabhakar ◽  
Giridharan Pytenkar ◽  
M Ramu
Keyword(s):  
Removal Rate ◽  
Research Work ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Casting Technique ◽  
Excessive Heat ◽  
Composite Tool ◽  
Al2o3 Particles ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract In this research work, an attempt was made to machine Ti6Al4V titanium alloy utilizing AA6061/10Gr composite tool. The composite tool was fabricated using stir casting technique and Al2O3 particles of size 5µm were incorporated in the dielectric fluid to enhance the machining performance. Experiments were conducted by varying Al203 concentration, pulse on time, current, and pulse off time, and the responses Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra) were recorded. Experiments runs were planned using Taguchi orthogonal array. The results revealed that adding powder increases MRR and TWR owing to the excessive heat generation and bridging effect respectively. The best surface finish was attained due to the increase in spark gap and complete flushing of machined debris. Coating of materials over the machined specimen was observed when the parametric value of Ton was higher than 60s under PMEDM conditions. Pits, craters and cracks were observed on the machined topography which was eliminated when 5g/l of Al2O3 particles were added to dielectric fluid. MEIOT technique was utilized for optimization and it was observed that Ton 15µs, Toff 4µs and current 7A and powder concentration of 10g/l results in best machining performance.

scholarly journals Evaluation of machining performance and multi criteria optimization of novel metal-Nimonic 80A using EDM

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Vikas K. Shukla ◽  
Rakesh Kumar ◽  
Bipin Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Minimum Energy ◽  
Process Parameter ◽  
Simultaneous Action ◽  
Peak Current ◽  
Nimonic 80A ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

AbstractThis study focused to machine novel Nimonic 80A through Electric Discharge Machine process. The process parameters are optimised to achieve high surface integrity along with high material removal rate (MRR) with minimum energy consumption. Central composite design along with analysis of variance technique has been applied to make correlation between the process parameter and responses. The developed model of surface roughness shows that the peak current and pulse-on time have significant effect whereas; a little effect of pulse-off time. The said result may be obtained due to simultaneous action of deposition and notching (removal) of material in order to form crater. In case of MRR, the pulse-on time and peak current are found as significant factors with increasing trend (i.e. when the input values are increased the MRR increases) whereas; a reverse trend is noticed with pulse-off time. The optimum values for maximum MRR (0.512444 gm/min) and minimum surface roughness (7.82203 µm) with 81% desirability are obtained for the process parameter as 13.49 A peak current, 150 µs pulse-on time and 4 µs pulse-off time.

Investigations on Effect of Electrode Polarity on Machining Performance of Ti-5Al-2.5Sn Alloy Using Electric Discharge Machining Process

2016 ◽  
Vol 1137 ◽  
pp. 39-51 ◽  
Author(s):  
Sanjeev Kumar ◽  
Rupinder Singh ◽  
Ajay Batish ◽  
T.P. Singh
Keyword(s):  
Removal Rate ◽  
Machining Process ◽  
Performance Criteria ◽  
Tool Electrode ◽  
Micro Hardness ◽  
Machining Performance ◽  
Peak Current ◽  
Electrode Polarity ◽  
Pulse On Time ◽  
Pulse Off Time

In electrical discharge machining (EDM) process, electrode polarity plays an important role during machining operation. This paper addresses the issues of EDM utilizing the positive and negative tool-electrode polarity to explore the effects on the performance criteria such as material removal rate (MRR), tool wear rate (TWR), surface roughness (SR) and micro-hardness during machining of Ti–5Al-2.5Sn (GradeVI) Ti alloy. The Ti-5Al-2.5Sn alloy was machined using copper-chromium electrode with positive and negative polarity by varying the peak current and pulse-on-time, while the pulse-off-time was kept constant. The result of study suggests that reverse polarity improves the MRR, TWR, SR while normal polarity improves the surface micro-hardness. The peak current has the maximum affect on machining performance for both types of polarities. Further the migration of different elements and formation of compounds on the machined surface was investigated using EDX and XRD analysis.

scholarly journals Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1105
Author(s):  
Nagarajan Lenin ◽  
Mahalingam Sivakumar ◽  
Gurusamy Selvakumar ◽  
Devaraj Rajamani ◽  
Vinothkumar Sivalingam ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Fly Ash ◽  
Process Control ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Machining Parameters ◽  
Control Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

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