Experimental investigations of slotted electrical discharge abrasive grinding of Al/SiC/Gr composite

2015 ◽  
Vol 231 (6) ◽  
pp. 945-955 ◽  
Author(s):  
Ravindra Nath Yadav ◽  
Vinod Yadava
Keyword(s):  
Metal Matrix ◽  
Electrical Discharge ◽  
Removal Rate ◽  
Wheel Speed ◽  
Machining Process ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Aluminum Silicon Carbide ◽  
Pulse On Time ◽  
Pulse Off Time

Machining of metal matrix composites has always been challenges for manufacturing engineers due to the presence of hard and brittle reinforced particles. In this article, a new way of alternate application of electrical discharge grinding and abrasive grinding has been applied through the use of slotted grinding wheel. The developed machining process has been named as slotted electrical discharge abrasive grinding. The performances of slotted electrical discharge abrasive grinding process are tested on aluminum–silicon carbide–graphite (Al/SiC/Gr) metal matrix composite workpiece. The experiments were performed using one parameter at a time approach considering the effect of current, pulse on-time, pulse off-time, wheel speed and grit number on material removal rate and average surface roughness. It has been found that current ranges from 3 to 15 A and wheel speed ranges from 700 to 1300 r/min are more appropriate for machining of Al/SiC/Gr composite material within the ranges of selected parameters.

Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V

2011 ◽  
Vol 418-420 ◽  
pp. 1478-1481 ◽  
Author(s):  
Manoj Modi ◽  
Gopal Agarwal
Keyword(s):  
Removal Rate ◽  
Surface Grinding ◽  
Machining Process ◽  
Diamond Surface ◽  
Experimental Investigations ◽  
Grinding Wheel ◽  
Hybrid Machining ◽  
Hard Materials ◽  
Hybrid Machining Process ◽  
Pulse On Time

Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

scholarly journals Optimization of Wire Cut Electro Discharge Machining Process Parameters for Aluminium 6082 by using Taguchi Technique

2021 ◽  
Vol 9 (12) ◽  
pp. 2257-2262
Author(s):  
Mahesh Muley
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract: The manufacturing industry is changing very drastically in all the aspect regarding the manufacturing technology as well as the quality concern as per as the quality is considered. Quality is becoming a significant trend in todays growing automobile industry. In the field of metal cutting operations, the surface roughness is becoming more dominant parameter as per as the quality of the component is considered. Electrical discharge machining is becoming a most powerful non conventional machining which is being widely used in the field of machining. Most specifically our work was conducted on the electrical discharge wire cut machining for achieving the desired surface roughness (Ra) and adequate material removal rate (MRR). The input parameter for our research work were selected as Peak current, pulse on time & pulse off time while the output parameter was selected as MRR and the surface roughness. Aluminum 6082 Grade material is used as a specimen and the research methodology implemented for the research work is taguchi and Anova. Keywords: Wire cut EDM, Taguchi, MRR surface roughness, Anova.

scholarly journals A Fuzzy Modelling for Selection of Machining Parameters in Wire Electrical Discharge Machining of D2 Steel

2020 ◽  
Vol 8 (5) ◽  
pp. 3045-3052
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fuzzy Model ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Selection Of

Wire Electrical Discharge Machining (WEDM) is a widely used non-traditional machining process used for machining of hard and difficult-to-machine materials. Proper selection of machining parameters in WEDM is required for better output performance, such as Material Removal Rate (MRR), Wire Wear Rate (WWR) and Surface Roughness (SR) etc. In the present paper, Pulse ON time, Pulse OFF time, Peak Current, Spark Voltage, Wire Feed and Wire Tension were taken as the input parameters to optimize MRR, WWR and SR. A set of 27 experiments were performed as per Taguchi Design. A Fuzzy model has been proposed to select the optimum values of machining parameters. The proposed fuzzy model was found to predict the experimental values with more than 90 percent accuracy.

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.

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.

scholarly journals Multi-Objective Optimization of Wire Electrical Discharge Machining of AL 2124/SIC Composite

2019 ◽  
Vol 9 (1) ◽  
pp. 2155-2163
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Strength ◽  
Wire Electrical Discharge Machining ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Predicted Values ◽  
Pulse On Time ◽  
Pulse Off Time

The growing demand for the use of high strength to weight alloys in industries for manufacturing complex structures challenges the machinability of such advanced materials. In the present investigation, the machinability of SiC particle reinforced Al 2124 composite was studied on Wire electrical discharge machining (WEDM). The process parameters namely pulse on-time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV) were optimized by utilizing the central composite design layout. The output responses such as kerf and material removal rate (MRR) were studied in detail. The single and multi-objective optimization was studied for a combination effect using Derringer’s desirability approach and Genetic Algorithm (GA). The experimental and predicted values for each response were validated at the optimized condition. The experimental results were found in line with the predicted values. Multi objective optimization of kerf and MRR by GA showing better result compared to RSM.

Experimental investigations on surface finish and microgeometry of helical gear in pulsed-electrochemical honing process

2019 ◽  
Vol 233 (10) ◽  
pp. 3364-3375 ◽  
Author(s):  
Pravin Rai ◽  
Neelesh K Jain ◽  
Sunil Pathak
Keyword(s):  
Surface Finish ◽  
Removal Rate ◽  
Experimental Investigations ◽  
Helical Gears ◽  
Mechanical Parts ◽  
Sandwich Type ◽  
Mechanical Elements ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Gear is one of the most vital mechanical elements for transmission of power and motion. It has been considered as one of the highest consumable mechanical parts. Surface attributes of the gears are most important elements to describe its operating performance, service life, and accuracy. Present work highlights the development of pulsed-electrochemical honing process to enhance the performance of gears by refining the variables of surface roughness, microgeometry, and material removal rate of 20MnCr5 alloy steel helical gears. Freshly designed sandwich type cathode gear has been developed which served as a tool in pulsed-electrochemical honing process. Investigations have been done on studying the effects and identifying the optimum values of four most important variables of pulsed-electrochemical honing process, namely applied voltage ( V), pulse-on time ( T on), pulse-off time ( T off), and finishing time ( t) on synchronized enhancement in surface finish and microgeometry. Results of the investigations reveal that T on as 6 ms, T off as 3 ms, t as 8 min, and V as 16 V yielded the best results for surface finish and microgeometry together.

scholarly journals Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

Coatings ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 590
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
Tomas Prokes ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Cutting Speed ◽  
Machining Process ◽  
Precision Machining ◽  
Machining Accuracy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Super Alloy ◽  
Machined Surfaces

Wire electrical discharge machining (WEDM) is an unconventional and very efficient technology for precision machining of the Nimonic C 263 super alloy, which is very widespread, especially in the energy, aerospace and automotive industries. Due to electrical discharge, defects in the form of cracks or burned cavities often occur on the machined surfaces, which negatively affect the correct functionality and service life of the manufactured components. To increase the efficiency of the machining of Nimonic C 263 using WEDM, in this study, extensive design of experiments was carried out, monitoring input factors in the form of machine parameters like Pulse off time, Gap voltage, Discharge current, Pulse on time and Wire feed, the output of which was comprehensive information about the behaviour of such machined surfaces, which allowed the optimization of the entire machining process. Thus, the optimization of the Cutting speed was performed in relation to the quality of the machined surface and the machining accuracy, as well as an analysis of the chemical composition of the machined surfaces and a detailed analysis of the lamella using a transmission electron microscope. A detailed study of the occurrence of surface or subsurface defects was also included. It was found that with the help of complex optimization tools, it is possible to significantly increase the efficiency of the machining of the Nimonic C 263 super alloy and achieve both financial savings in the form of shortened machine time and increasing the quality of machined surfaces.

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