scholarly journals Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

2014 ◽  
Vol 2014 ◽  
pp. 1-16 ◽  
Author(s):  
Teepu Sultan ◽  
Anish Kumar ◽  
Rahul Dev Gupta
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Wear Rate ◽  
Response Surface ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electrode Wear Rate ◽  
Pulse On Time

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

scholarly journals Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Energies ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 38 ◽  
Author(s):  
Misbah Niamat ◽  
Shoaib Sarfraz ◽  
Wasim Ahmad ◽  
Essam Shehab ◽  
Konstantinos Salonitis
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Multi Objective Optimization ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

scholarly journals Optimization of EDM Process Parameter for MRR and SR of 17- 4 PH Steel Using Response Surface Methodology

2018 ◽  
Vol 1 (2) ◽  
Author(s):  
SHUBHRATA NAGPAL
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Pulse On Time

In the present work, an attempt has been made for material removal rate and surface roughness by response surface optimization techniques in Electrical discharge machining. Electrical discharge machining, commonly known as EDM, is a process that is used to remove metal through the action of an electrical discharge of short duration and high current density between the work piece and too. This work presents the results of a mathematical investigation carried out to the effects of machining parameters such as current, pulse on time, pulse off time and lift time on material removal rate and surface roughness in electrical discharge machining of 17-4 PH steel by using copper electrode. Response surface methodology and ANOVA techniques are used for data analysis to solve the multi-response optimization. To validate the optimum levels of the parameter, confirmation run was performed by setting the parameters at optimum levels. Material Removal Rate during the process has been taken as productivity estimate with the objective to maximize it. With an intention of minimizing surface roughness is been considered as most important output parameter. It is found that the good agreement of that current is most significant parameter for material removal rate and less for surface roughness followed by pulse on time and lift time.

PENGARUH VARIABEL PEMOTONGAN TERHADAP KEAUSAN ELEKTRODA DAN BENDA KERJA PADA PROSES EDM

ROTASI ◽  
2014 ◽  
Vol 16 (4) ◽  
pp. 9
Author(s):  
Petrus Londa
Keyword(s):  
Wear Rate ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Signal To Noise Ratio ◽  
Electrode Wear ◽  
Signal To Noise ◽  
Electrode Wear Rate

Keausan elektroda pada proses EDM die sinking adalah peristiwa yang tidak dapat di hindari, namun dengan mengatur variabel pemotongan yang sesuai, diharapkan keausan yang terjadi se-minim mungkin sehingga dapat menjamin tingkat akurasi ukuran pada benda kerja yang di hasilkan. Pada penelitian ini di pilih metode Taguchi untuk menentukan variabel pemotongan yang optimum pada elektroda tembaga dan benda kerja dari bahan K460 (amutit S). Taguchi L9 orthogonal array, signal-to-noise ratio (S/N ratio) dan analysis of variance (ANOVA) dapat menentukan performa variabel proses EDM (PON, POFF, QDON dan GAP) dengan parameter yang di teliti adalah Electrode Wear Rate (EWR) dan Material Removal Rate (MRR). Hasil dari eksperimen tersebut di tampilkan dalam bentuk tabel-tabel dan grafik

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.

Parameters Optimization of the Ultrasonic External Cylindrical Lapping Process for Nano ZTA Engineering Ceramics Using Response Surface Methodology

2007 ◽  
Vol 364-366 ◽  
pp. 733-738
Author(s):  
Feng Jiao ◽  
Bo Zhao ◽  
Chuan Shao Liu ◽  
Xun Sheng Zhu
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Parameters Optimization ◽  
Response Models ◽  
Engineering Ceramics ◽  
Surface Response

Aimed at the precision machining characteristics of nano ZTA engineering ceramics external cylindrical components, ultrasonic aided lapping experiments were carried out adopting inhouse developed ultrasonic external cylindrical lapping device with solid abrasive material. To obtain minimum surface roughness with constraint of the material removal rate, response surface methodology (RSM) was adopted to analyze the experimental data, and suitable experiment design was chosen to fit the response surface in this research. Second-order surface response models of surface roughness and material removal rate were developed respectively, and the influence laws of lapping parameters on surface roughness and material removal rate were clarified according to the built models. Finally, parameters optimization of the ultrasonic external cylindrical lapping process for nano ZTA engineering ceramics was realized using surface response methodology.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

2011 ◽  
Vol 189-193 ◽  
pp. 1393-1400 ◽  
Author(s):  
M.M. Rahman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

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