Investigation of Surface Roughness for Inconel 718 in Blind Hole Drilling with Rotary Tool Electrode

2019 ◽  
Vol 18 (03) ◽  
pp. 379-394
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Work Piece ◽  
Tool Electrode ◽  
Tool Diameter ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Tool Rotation ◽  
Off Time ◽  
Time Pulse

The research investigation reported on the effect of machining parameters on surface roughness (Ra) in electric discharge drilling of Inconel 718. Machining was done by using a copper tool electrode. Machining was conducted by considering different process parameters viz. tool diameter, discharge current, pulse on time, pulse off time, tool rotation and depth of hole. Optical surface profiler was used to measure surface roughness of drilled hole in work-piece. Design of experiment was created by Taguchi method based L18 orthogonal array. For minimum surface roughness, optimum parameters were found using Analysis of variance (ANOVA). Based on analysis, it is found that pulse off time, pulse on time and tool rotation are the most significant parameters that affect the surface roughness. Tool diameter is the less significant parameter that affects the surface roughness. Regression analysis was used to predict a value for minimum surface roughness. The scanning electron microscope (SEM) images were used to identify the microstructure of the drilled hole in Inconel 718 work-piece. Interaction plots and residual plot have been plotted for surface roughness to identify the interaction between parameters and residual errors, respectively.

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.   

A Comparison of the Effects of Wire Electrical Discharge Machining Parameters on the Processing of Traditionally Manufactured and Additively Manufactured 316L Stainless Steel Specimens

2018 ◽  
Author(s):  
Gregory Bicknell ◽  
Guha Manogharan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
316L Stainless Steel ◽  
Machining Parameters ◽  
Wire Edm ◽  
Machining Time ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electric discharge machining (EDM) is a non-traditional machining method that has the ability to machine hard, conductive materials, with no force and high precision. This technology is used in industries, like the aerospace industry, to create precision parts used in high stress applications. Wire EDM is also commonly used in additive manufacturing (AM) applications to remove printed parts from the base-plates onto which they are printed. Numerous studies show the effects of EDM parameters, like pulse-on time, pulse-off time, and cutting voltage, on the processing of traditionally fabricated metal parts. However, very few studies identify how the parameters of wire EDM affect the processing of AM parts. This paper studies the effect of wire EDM pulse-on time, pulse-off time, and cutting voltage on the machining time, surface roughness, and hardness of additively manufactured 316L stainless steel cylinders. The effects of these wire EDM parameters are then tested on the machining time, surface roughness, and hardness of wrought 316L stainless steel cylinders. It was found that machining time of AM samples was statistically significantly lower than wrought samples and also had better surface finish and lower surface hardness.

scholarly journals Parametric Study of Machining on EN31 and EN19 Alloy Steels in WEDM to Analyze the Effect on Surface Roughness

2018 ◽  
Vol 7 (2) ◽  
pp. 36-42
Author(s):  
Ramandeep Singh ◽  
Ashok Kumar
Keyword(s):  
Surface Roughness ◽  
Input Parameter ◽  
Hard Materials ◽  
Current Voltage ◽  
Alloy Steels ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

Wire EDM can machine hard materials as well as alloys. Thus this study aims to analyze the effect of process parameters in WEDM on EN31 and EN19 alloy steels. The parameters selected for the optimization were Work material, Pulse on Time, Pulse off Time, Current, Voltage and Wire Feed for improvement in surface roughness. Taguchi L18 Orthogonal array was used for the best combination of experiment. The output responses were analyzed by ANOVA (Analysis of variance). The ANOVA result indicated that there is a significant effect on improvement in surface roughness when machining with all these six input parameter and coated wire. According to the present investigation, voltage was found to be the most significant factor followed by Ton and current, which affect the improvement in surface roughness.

Application of Machine Learning Techniques for Multi Objective Optimization of Response Variables in Wire Cut Electro Discharge Machining Operation

2019 ◽  
Vol 969 ◽  
pp. 800-806
Author(s):  
Sidharth Kumar Shukla ◽  
Amrita Priyadarshini
Keyword(s):  
Machine Learning ◽  
Surface Roughness ◽  
Gradient Descent ◽  
Descent Method ◽  
Kerf Width ◽  
Gradient Descent Method ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire Cut Electrical Discharge Machining (WEDM) is a non-conventional thermal machining process which is capable of accurately machine alloys having high hardness or part having complex shapes that are very difficult to be machined by the conventional machining processes. The WEDM finds applications in automobiles, aero–space, medical instruments, tool and die industries, etc. The input parameters considered for WEDM are pulse on time, pulse off time, flushing pressure, servo voltage, wire feed rate and wire tension. Performance of WEDM is mainly assessed by output variables such as, material removal rate (MRR), kerf width (Kw) and surface roughness (Ra) of the work piece being machined. Looking at the need of a suitable optimization model, the present work explores the feasibility of machine learning concepts to predict optimum surface roughness and kerf width simultaneously by making use of experimental data available in the literature for machining of Hastelloy C– 276 using WEDM. In most of the literatures, single objective optimization has been carried out for predicting optimum cutting parameters for WEDM. Hence, the present work presents a methodology that makes use of a machine learning algorithm namely, gradient descent method as an optimization technique to optimize both surface roughness and kerf width simultaneously (multi objective optimization) and compare the results with the existing literatures. It was observed that the input parameters such as pulse on time, pulse off time, and peak current have significant effect on both surface roughness and kerf width. The gradient descent method was successfully used for predicting the optimum values of response variables.

Evaluating Influences of Input Parameters on Surface Roughness in Sinking EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 85-90
Author(s):  
Tran Thi Hong ◽  
Nguyen Anh Tuan ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Work Piece ◽  
Enabling Factors ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time ◽  
Optimum Input

The input parameters in the process of sinking Electrical Discharge Machining (EDM) are the essential enabling factors that need to be determined. In the present work, the influences of the EDM input parameters containing pulse on time (Ton), pulse off time (Toff), discharge current (IP), Server voltage (SV), work-piece diameter (dw) on the surface roughness (SR) in sinking EDM cylindrical shaped part of 9CrSi material were investigated. Taguchi technique and analysis of variance (ANOVA) have been used to identify the weight of EDM factors on SR. The results show that the impact level of Ton, Toff, IP, SP, and dw are 65.55%, 8.66%, 19.17%, 3.14%, and 0.76%, respectively. By analyzing the experimental results, optimum input parameters with the Ton of 6 ms, Toff of 30 ms, IP of 9A, SP of 3V, and dw of 10mm have been determined, that allow getting the best surface roughness.

Impact Assessment of Input Factors on Tool Electrode Wear in Die Sinking EDM of Steel EN43CrMo4

2017 ◽  
Vol 756 ◽  
pp. 127-135
Author(s):  
Slavomíra Hašová ◽  
Ľuboslav Straka ◽  
František Špalek
Keyword(s):  
Electrode Material ◽  
Graphite Electrode ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Workpiece Material ◽  
Relative Wear ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

The paper deals with the wear of tool electrodes for Die Sinking EDM. In the experiment were used the electrodes of copper and graphite. The workpiece material was steel EN43CrMo4. For the assessment the effects of each parameter was used the statistical method Design of Experiments (DOE). Assessed input factors were the peak current, pulse on-time, pulse off-time, and the electrode material. The result of the effects of each input factors was tool electrode wear. For calculating the relative wear of electrodes was used the percentage of the ratio of the electrode and the workpiece weight. The results show that the expression of the relative wear in practice can be described as a method unusable due to the absorption of the graphite electrode used in the experiment.

Investigation of the Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloy

2012 ◽  
Vol 472-475 ◽  
pp. 78-81 ◽  
Author(s):  
Mohinder Pal Garg ◽  
Ajai Jain ◽  
Gian Bhushan
Keyword(s):  
Surface Roughness ◽  
Water Pressure ◽  
Peak Voltage ◽  
Peak Current ◽  
Wire Breakage ◽  
Pulse Peak ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the Wire Electric Discharge Machining of Titanium alloy 6-2-4-2.Eight process parameters namely pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed, wire tension, water pressure, pulse peak voltage and servo feed are varied to study their effect on surface roughness and wire breakage. The experiments are conducted using one-factor-at-a-time approach. Moreover, a few random experiments are also carried to study the phenomenon of wire breakage precisely. The study revealed that surface roughness is directly affected by the pulse-on time, pulse-off time, peak- current, spark gap set voltage and wire tension. Wire feed, Water pressure and pulse peak voltage have negligible effect on the surface roughness. Moreover, wire breakage is predominantly dictated by all the parameters except peak current and pulse peak voltage. An optimum range of input parameters has been bracketed as the final outcome for cutting in terms of surface roughness and to minimize the wire breakage frequency.

A Study on Surface Roughness and Cutting Width for Circular Contour Machining of Stir Cast AA6063/SiC Composites in WEDM

2017 ◽  
Vol 13 (10) ◽  
pp. 6524-6530
Author(s):  
I. Balasubramanian
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Stir Casting ◽  
Circular Contour ◽  
Sic Composites ◽  
Contour Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electrical discharge machining is used in machining electric conductive materials with intricate shapes and profiles. This paper presents an experimental investigation on the influence of cutting conditions of WEDM on surface roughness and cutting width of machining of AA6063/SiC composites. Here a semi cylindrical piece is removed from a rectangular plate of AA6063/SiC composites plate fabricated with reinforcing SiC in 0%, 5%, 10% and 15% weight fractions through stir casting. The effect of WEDM parameters such as pulse on time, pulse off time and peak current on surface roughness and cutting width on different composition of AA6063/SiC were analyzed for circular contour machining. The experimental results show that increase in percentage of SiC has high influence in mechanical behavior of AA6063/SiC composites and the effect of pulse on time is very significant in reducing the surface roughness and pulse off time plays an important role in producing minimum cutting width.  

Experimental Evaluation on Corner Accuracy in WEDM for Aluminium 6061 Alloy

2021 ◽  
pp. 96-113
Author(s):  
Debal Pramanik ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Thermal Process ◽  
Electrical Discharge Machining ◽  
Sharp Corner ◽  
Proposed Model ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

An important electro-thermal process known as wire electrical discharge machining (WEDM) is applied for machining of conductive materials to generate most precisely. All cutting inaccuracies of WEDM arise out of the major cause of wire bending. At the time of cutting a sharp corner or cut profile, bending of the wire leads to a geometrical error on the workpiece. Though this type of error may be of a few hundred microns, it is not suitable for micro applications. In this research study, an experimental investigation based on response surface methodology (RSM) has been done on wire EDM of Aluminium 6061 t6 alloy. This chapter studies the outcome of input process variables (i.e., wire feed rate, pulse on time, pulse off time, and gap voltage) on machining output responses (i.e., corner inaccuracy) extensively. Experimental validation of the proposed model shows that corner inaccuracy value may be reduced by modification of input parameters.

Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

2019 ◽  
Vol 969 ◽  
pp. 644-649
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Work Piece ◽  
Tool Electrode ◽  
Affecting Factors ◽  
Inconel 718 Alloy ◽  
Electrical Discharge Drilling ◽  
Pulse On Time

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

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