Modeling and Spark Erosion Drilling Process Optimization of Inconel 718 Using RSM Technique

2019 ◽  
Vol 18 (01) ◽  
pp. 57-83 ◽  
Author(s):  
Rajeev Kumar ◽  
Somnath Chattopadhyaya ◽  
G. K. Singh ◽  
Umesh Kumar Vates
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Discharge Current ◽  
Inconel 718 ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining with rotary tool is known as electric discharge drilling (EDD) which is being widely used for machining the difficult-to-cut materials like super alloy, ceramics and composite materials. Present research work has been introduced to find the impact of four influencing input factors discharge current (C), pulse off time ([Formula: see text]), pulse-on time ([Formula: see text]) and drill speed (S) on the response, tool wear rate (TWR), metal removal rate (MRR) and Centre line average value of surface roughness (Ra). The spark erosion drilling was performed on the Inconel 718 with rotating copper electrode. The major performances characteristics material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) are to be evaluated with consultation of Response Surface Methodology (RSM) techniques. The central composite rotatable design (CCRD) has been reported to plan the experimental design and developing the model for prediction of data within the range of investigation. ANOVA test was also carried out to check the adequacy for development of models. It has been evaluated that discharge current, [Formula: see text], and [Formula: see text] have been found as most significant factors that effects on the performance measures. The models have 86.02, 84.29, and 83.15% values of correlation coefficient (R2) for MRR, TWR and Ra whereas the adjusted R2 (R2 adj) are 73.80%, 70.55%, and 68.41% for MRR, TWR and SR, respectively.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

ELECTRICAL DISCHARGE MACHINING OF Al/7.5% Al2O3 MMCs USING ROTARY TOOL AND Al2O3 POWDER

2017 ◽  
Vol 24 (02) ◽  
pp. 1750018 ◽  
Author(s):  
SAEED DANESHMAND ◽  
BEHNAM MASOUDI ◽  
VAHID MONFARED
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Pulse On Time

Nowadays, composites are used in different parts of industries and it is one of the most important subjects. The most widely used reinforcements in metal matrix composites are Al2O3 and SiC fibers and particles which may be used in cutting-edge functional and structural applications of aerospace, defense, and automobile industries. Depending on the type of powder used, composite materials are difficult to machine by conventional cutting tools and methods. The most appropriate way for machining of these composites is electro discharge. For the reason of improving the surface quality, tool wear rate and material removal rate and reducing the cracks on the surface, Al2O3 powder was used. In this study, the effect of input parameters of EDM such as voltage, pulse current, pulse on-time and pulse off-time on output parameters like material removal rate, tool wear rate and surface roughness in both conditions of the rotary tool with powder mixed dielectric EDM and the stationary tool excluding powder mixed dielectric were investigated. The critical parameters were identified by variance analysis, while the optimum machining parameter settings were achieved via Taguchi method. Results show that using of powder mixed dielectric and rotary tool reduce the tool wear rate, surface roughness and the cracks on the surface significantly. It is found also that using of powder mixed dielectric and rotary tool improve the material removal rate due to improved flushing action and sparking efficiency. The analysis of variance showed that the pulse current and pulse on-time affected highly the MRR, TWR, surface roughness and surface cracks.

scholarly journals Tool Wear Rate on Inconel 718 using W-Powder Mixed Electric Discharge Drilling

2020 ◽  
Vol 9 (5) ◽  
pp. 1431-1435
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Removal Rate ◽  
Research Work ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Electrical Discharge Drilling ◽  
Pulse Off Time

Electrical Discharge Drilling (EDD) is an unconventional manufacturing process with large industrial performances. Addition of powder particles in dielectric changes some process variables and machines hard and hard to cut materials with greater surface finish high tolerance and accuracy to accomplish a superior material removal rate with a reduced Tool Wear Rate (TWR). This research work explores the performance of TWR on Tungsten Powder Mixed Electrical Discharge Drilling (W-PMEDD) on Inconel 718 super alloy. The input machining parameters of Peak Current (Ip ) Pulse on (Ton) and Pulse off time (Toff) and the output measure of TWR were examined by Response Surface Method (RSM). Analysis of Variance was used to evaluate the effect of the machining parameters and it is concluded that Ip, Ton and Toff are the most significant parameters while machining of W-PMEDD on Inconel 718.

Experimental Investigation of EDM Parameters on Al-LM6/SiC/B4C Hybrid Composites

2018 ◽  
Vol 877 ◽  
pp. 149-156 ◽  
Author(s):  
Manish Shukla ◽  
Pankaj Agarwal ◽  
Mohan Kumar Pradhan ◽  
S.K. Dhakad
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Material Removal ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Widespread Application ◽  
Pulse On Time

In this work, a Material removal rate (MRR), Tool wear rate (TWR), Radial and overcut (ROC), a study on the die-sinking Electrical discharge machining (EDM) of Al-LM6/SiC/B4C hybrid composites has been carried out. The selection of above-mentioned hybrid composite was made considering its widespread application in aerospace, automotive, defense, biomedical and marine industries, due to its light weight and higher mechanical properties. This experiment was made only for the finish stage and has been carried out on the influence of four design factors: composition, discharge current (Ip), Pulse-on-time (Ton), Radial overcut (ROC) and Duty factors (Tau), over the previously mentioned, responded variables. This has been done by means of the method of design of experiment (DOE) which allows us to carry out the above-mentioned analysis performing a relatively small number of experiments. The study indicates that when discharge current (Ip) increases, Material removal rate increased. In the case of Tool wear rate the most influencing factor is discharge current, then pulse on time. In radial over cut most influence factor is discharge current then pulse on time, duty factor and composition has least.

Fabrication and experimental investigation of magnetic field assisted powder mixed electrical discharge machining on machining of aluminum 6061 alloy

2019 ◽  
Vol 233 (12) ◽  
pp. 2283-2291 ◽  
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Pulse On Time

Magnetic field assisted powder mixed electrical discharge machining is a hybrid machining process with suitable modification in electrical discharge machining combining the use of magnetic field and fine powder in the dielectric fluid. Aluminum 6061 alloy has found highly significance for the advanced industries like automotive, aerospace, electrical, marine, food processing and chemical due to good corrosion resistance, high strength-to-weight ratio, ease of weldability. In this present work, magnetic field assisted powder mixed electrical discharge machining setup was fabricated and experiments were performed using one factor at a time approach for aluminum 6061 alloy. The individual effect of machining parameters namely, peak current, pulse on time, pulse off time, powder concentration and magnetic field on material removal rate and tool wear rate was investigated. The effect of peak current was found to be dominant on material removal rate and tool wear rate followed by pulse on time, powder concentration and magnetic field. Increase in material removal rate and tool wear rate was observed with increase in peak current, pulse on time and a decrease in pulse off time, whereas, for material removal rate increases and tool wear rate decreases up to the certain value and follow the reverse trend with an increase in powder concentration. Material removal rate was increased and tool wear rate was decreased with increase in magnetic field.

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 An overview of conventional and non-conventional techniques for machining of titanium alloys

2020 ◽  
Vol 7 ◽  
pp. 34 ◽  
Author(s):  
Samuel Ranti Oke ◽  
Gabriel Seun Ogunwande ◽  
Moshood Onifade ◽  
Emmanuel Aikulola ◽  
Esther Dolapo Adewale ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Metal Removal ◽  
Removal Rate ◽  
High Volume ◽  
Future Research ◽  
Tool Wear Rate ◽  
The Common

Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

scholarly journals Machinability Of Shape Memory Alloy Using Electro Spark Erosion Process 

2021 ◽  
Author(s):  
Adam Khan M ◽  
Winowlin Jappes J T ◽  
Samuel Ratna Kumar P S ◽  
Mashinini P M
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Shape Memory ◽  
Applied Voltage ◽  
Material Removal ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Pulse On Time ◽  
The Impact

Abstract In this research work, the nickel – titanium based shape memory alloys are machined using electro spark machining process. The influence of the input process for electro spark production is studied in detail. From the analysis, the tool wear rate (TWR), surface roughness, and material removal rate (MRR) are investigated. The intensity of the electro spark produced at minimum pulse on-time 10 µs and maximum applied voltage (60 V). Variation in MRR is wide for a minimum pulse on time with low applied voltage. The surface roughness of the machined surface is also directly influenced by the in – efficient spark produced. The copper electrode with increase pulse duration the alloy behaves like a strong conductor to transmit electrical energy between the electrode and work material. The contribution of pulse on-time is maximum for material removal and tool wear rate. However, the surface finish depends on the applied voltage of the process designed. The impact on machined surfaces, micro-cracks, electro-discharge carter's, and recast material due to electrical discharge were assessed using a scanning electron microscope and energy-dispersive X-ray spectroscopy (EDX) analysis. The experimental value shows that material removal depends on the pulse on process timings and applied voltage. Thus, by using mathematical analysis the influence of (electric discharge machining) EDM process parameters was evaluated.

scholarly journals Multi-Response Optimization of process Parameter in Vertical Milling Machine of EN 31 Using Taguchi Method

2021 ◽  
Vol 23 (11) ◽  
pp. 228-235
Author(s):  
Sunil Kumar ◽  
◽  
P.N . Rao ◽  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Tool Wear Rate ◽  
Vertical Milling Machine ◽  
En 31

The purpose of this experimental research is to compare the effectiveness of using Taguchi approaches for multi-response optimization of process parameters in Vertical Milling Machine of EN 31 Material intending to minimize surface roughness and tool wear rate while maximizing material removal rate to improve the productivity of the process with coated carbide insert. Taguchi L9 and Annova have been applied for experimental design and analysis. This experiment shows that feed and depth of cut are factors that are important for tool wear, Depth of cut is a notable factor for Material Removal Rate and feed is the most notable factor for surface roughness. Spindle speed has little effect on tool wear rate, surface roughness, and material removal rate. Mathematical models for three response parameters i.e. tool wear rate, surface roughness, and material removal rate were obtained by regression analysis

Fuzzy based multi-response optimization: a case study on EDM machining process

2021 ◽  
Vol 3 (7) ◽  
Author(s):  
Jambeswar Sahu ◽  
Sonam Shrivastava
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Fuzzy System ◽  
Material Removal ◽  
Optimal Parameter ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Neuro Fuzzy ◽  
Single Response ◽  
Pulse On Time

Abstract The current study challenges the multi-objective optimization of electric discharge machining (EDM) parameters. EDM is used for creating profiles by machining of workpiece that are difficult to machine by conventional method. In the current work four responses such as material removal rate (production rate), tool wear rate, surface roughness (quality) and circularity (profile) are collectively investigated with varying controlling parameters. The human decision for best combination of controlling parameters for highest performance has uncertainties, which results in inferior solution. The multiple responses along with uncertainties and impreciseness can be addressed by combining a neuro-fuzzy system with particle swarm optimization (PSO). To illustrate the superiority of the proposed approach a set of experiment have been conducted in EDM process using AISI D2 tool steel as workpiece and brass tool. The experimental plan was made according to the Box-Behnken response surface methodology design with four process parameters namely discharge current, pulse-on-time, duty factor, and flushing pressure. The four response parameters such as material removal rate, tool wear rate, surface roughness, and circularity of machined components were optimized simultaneously. One unique Multi-response Performance Characteristic Index was obtained by combining the four responses using the proposed neuro-fuzzy technique. A regression model was developed on single response and optimized by PSO to obtain the optimal parameter setting. An experiment was conducted on optimal parameter to test the optimum performance. It is observed that the EDM responses were affected significantly by discharge current and pulse-on-time. The increase in pulse-on-time leads to larger surface cracks and more micro-pores on the machined surface. Article Highlights RSM was proven to be an effective statistical tool for reducing the experimental runs, and also establishes the relation between multiple inputs and single output. The neuro-fuzzy system combined with PSO results a suitable model to convert multiple response into an equivalent single response. The presented approach can be a practical method for situations where multiple conflicting objectives are needed to be optimized at the same time.

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