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.

CHARACTERIZATION OF ZrB2-SiC COMPOSITES WITH AN ANALYTICAL STUDY ON MATERIAL REMOVAL RATE AND TOOL WEAR RATE DURING ELECTRICAL DISCHARGE MACHINING

2016 ◽  
Vol 40 (3) ◽  
pp. 331-349 ◽  
Author(s):  
S. Sivasankar ◽  
R. Jeyapaul
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Relative Density ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Tool Materials

This research work concentrates on Electrical Discharge Machining (EDM) performance evaluation of ZrB2- SiC ceramic matrix composites with different tool materials at various machining parameters. Monolithic ZrB2 possesses lower relative density (98.72%) than composites. ZrB2 with 20 Vol.% of SiC possesses 99.74% of the relative density with improved hardness values. Bend strength and Young’s modulus increase with SiC addition until it reaches 20 Vol% and then decreasing. EDM performance on tool materials of tungsten, niobium, tantalum, graphite and titanium at various levels of pulse on time and pulse off time are analyzed. Graphite produces the best Material removal rate (MRR) for all the workpieces. Tool wear rate decreases with melting point and thermal conductivity of the tool material.

Analysis of MRR and TWR on OHNS Die Steel with Different Electrodes Using Electrical Discharge Machining

2016 ◽  
Vol 22 ◽  
pp. 112-120 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Tool Wear Rate

Electrical Discharge Machining is a machining method primarily used for hard metals or those that are impossible to be machined with traditional techniques. The experimental investigation of material removal rate and tool wear rate during machining of oil hardened non-shrinking steel with brass and copper electrodes using EDM machine was carried out in this paper. This investigation presents the analysis and evaluation of heat affected zones and surface finish of the work piece using different tool electrodes and varying the machine parameters. The commercial grade kerosene oil has been used as dielectric fluid. The effect of various important EDM parameters such as discharge current (Ip) 2 to12A, pulse duration (Ton and Toff) and sparking voltage (V) of 80±5% have been used to yield the response in terms of Material Removal Rate (MRR) and Tool Wear Rate (TWR). Further a detailed analysis of the heat affected regions was also been carried out by using scanning electron microscopy.

PENGARUH PARAMETER PROSES EDM DIE SINKING TERHADAP LAJU PELEPASAN BAHAN DAN LAJU KEAUSAN ELEKTRODA

2019 ◽  
Vol 1 (2) ◽  
pp. 105-112
Author(s):  
Nafsan Upara ◽  
Dimas Anugrah Destianto
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate

Electrical Discharge Machining (EDM) merupakan pemesinan nonkonvensional yang memanfaatkan proses konversi listrik dan panas, dimana energi listrik digunakan untuk memunculkan loncatan bunga api dan proses pelepassan bahan terjadi akibat energi panas yang ditimbulkan dari bunga api tersebut.Keausan elektroda pada proses EDM die sinking merupakan peristiwa yang tidak dapat di hindari, namun dengan mengatur parameter pemotongan yang sesuai, diharapkan keausan yang terjadi pada elektroda se-minim mungkin dan pemakanan benda kerja semaksimal mungkin sehingga didapati tingkat akurasi ukuran pada benda kerja. Pada penelitian ini menggunakan metode Taguchi  dengan L8 orthogonal array memakai elektroda bahan tembaga dan benda kerja material SKS 3. S/N ratio dan ANOVA menentukan performa parameter proses EDM dengan respon yang di teliti adalah Material Removal Rate (MRR) dan Tool Wear Rate (TWR). Hasil dari eksperimen tersebut menghasilkan parameter optimum Aruslevel 2= 6 A; Ponlevel 1=100 µs dan Pofflevel 1=50µs.

Experimental investigation of the effect of tool material on the performance of AISI 4140 steel in the rotary near dry electrical discharge machining

2020 ◽  
Vol 234 (4) ◽  
pp. 308-317
Author(s):  
Fereydoon Rajabinasab ◽  
Vahid Abedini ◽  
Mohammadjafar Hadad ◽  
Ramezanali Hajighorbani
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Material ◽  
Tool Wear Rate ◽  
Dry Electrical Discharge Machining

This research conducts in three sections. The first section studies the effect of tool materials and gases on rotary workpiece electrical discharge machining. During the experiments, the effects of three kinds of tool materials (Cu, Cu-Cr, and Cu-Sn) and three types of industrial gases (air, argon, and CO2) on the material removal rate, tool wear rate, and workpiece surface roughness are investigated. The second is a comparison between rotary workpiece, rotary tool, and the fixed workpiece by choosing the appropriate tool material and gas in order to observe the effect of workpieces rotation on the process. Finally, another comparison has been done between wet electrical discharge machining and near dry electrical discharge machining of the fixed workpiece in order to study the effect of the dielectric. The results show the copper tool has the best performance compared with other tools. Scanning electron microscopy output shows the Cu-Sn tool creates shallow micro-cracks on the surface. Air and CO2 gases have the higher material removal rate in low current, but argon has better function than other gases in high current. In addition, a rotational speed causes an increase in material removal rate and tool wear rate and surface roughness decrease in near dry electrical discharge machining. The level of tool wear rate has decreased by 14% in the rotary workpiece compared with the rotary tool.

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.

Process Research on High-Speed Small Hole Drilling by EDM Combined with Magnetic Field and Water Dispersant

2011 ◽  
Vol 189-193 ◽  
pp. 269-272 ◽  
Author(s):  
Ming Rang Cao ◽  
Xiao Di Geng
Keyword(s):  
Magnetic Field ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Hole Drilling ◽  
Tool Wear Rate ◽  
The Magnetic Field

The mechanism that the magnetic field and the dispersant are helpful to chip removal, to improve the material removal rate (MRR) and to reduce the tool wear rate (TWR) was analyzed in detail.The corresponding experiments were conducted based on theoretical analysis. The experimental results show that adding a certain proportion of dispersant into the dielectric fluid and introducing the magnetic field for high speed small hole drilling by EDM can greatly improve the material removal rate and significantly decrease the tool wear rate.

Material Removal Rate and Tool Wear Ratio for Powder Mixed Dielectric Based Electric Discharge Machining

2021 ◽  
Vol 13 (1) ◽  
Author(s):  
Gurmail Singh Malhi ◽  
Gurpreet Singh Sokhal ◽  
Gurprinder Singh Dhindsa ◽  
Kamaljit Singh Sokhal
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Study ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Tool Wear Ratio

Electrical discharge machining (EDM) is used in die making and aerospace industries. This paper presents the performance study of the conventional EDM when used with powder mixed dielectric. Copper, graphite and mix (copper and graphite) were used. Pulse on, pulse off and current are the parameters which were varied at three levels. Copper, graphite and tungsten-copper were used as the electrode. The material removal rate and tool wear rate are assessed using design of experiments.

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