Modelling of material removal rate in the magnetic field and air-assisted electrical discharge machining

2019 ◽  
Vol 234 (7) ◽  
pp. 1286-1297
Author(s):  
Hardik Beravala ◽  
Pulak M Pandey
Keyword(s):  
Magnetic Field ◽  
Material Removal Rate ◽  
Plasma Column ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Air Pressure ◽  
Machining Process

In the present research work, an attempt has been made to develop the mathematical model to predict the material removal rate in the electrical discharge machining process when the assistance of air and magnetic field is provided together. The proposed model incorporates the physical phenomenon occurred during electrical discharge machining such as the plasma column expansion and reduction in the mean free path of electron in the plasma column due to magnetic field. In addition, the model incorporates the effect of air on the material removal rate. The developed model correlates the material removal rate with the process parameters such as the peak current, pulse duration, duty cycle, air pressure and magnetic flux density. The experimental data were used to evaluate the constants for district processing conditions. The relation between air pressure and breakdown voltage in the liquid-air mixed dielectric has been established experimentally. The obtained expression of material removal rate has been validated for the experimental conditions other than that used for obtaining constants. The results show less than 10% error in the prediction by the model over the respective experimental values.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

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.

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.

Comparative evaluation of powder-mixed and ultrasonic-assisted rough die-sinking electrical discharge machining based on pulse characteristics

2019 ◽  
Vol 233 (14) ◽  
pp. 2515-2530 ◽  
Author(s):  
R Rajeswari ◽  
MS Shunmugam
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Machining Process ◽  
Machined Surface ◽  
Ultrasonic Assisted ◽  
Pulse On Time

Electrical discharge machining is used in the machining of complicated shapes in hardened molds and dies. In rough die-sinking stage, attempts are made to enhance material removal rate with a consequential reduction in cycle time. Powder mix and ultrasonic assistance are employed in the electrical discharge machining process to create gap conditions favoring material removal. In the present work, experiments are carried out on hardened D3 die steel using full-factorial design based on three levels of voltage, current and pulse on time. The gap phenomena in graphite powder-mixed and ultrasonic-assisted rough electrical discharge machining are studied using a detailed analysis of pulse shapes and their characteristic trains. Two new parameters, namely, energy expended over a second ( E) and performance factor ( PF) denoting the ratio of energy associated with sparks to total discharge energy, bring out gap conditions effectively. In comparison with the conventional electrical discharge machining for the selected condition, it is seen that the graphite powder mixed in the dielectric enhances the material removal rate by 20.8% with E of 215 J and PF of 0.227, while these values are 179.8 J and 0.076 for ultrasonic-assisted electrical discharge machining with marginal reduction of 3.9%. Cross-sectional images of workpieces also reveal the influence of electrical discharge machining conditions on the machined surface. The proposed approach can be extended to different powder mix and ultrasonic conditions to identify condition favoring higher material removal.

scholarly journals Analisa MRR, EWR, DOC terhadap Beberapa Material Elektroda pada Proses EDM Die Sinking

ROTASI ◽  
2019 ◽  
Vol 21 (1) ◽  
pp. 1
Author(s):  
Petrus Londa
Keyword(s):  
Wear Rate ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrode Wear ◽  
Conventional Machining

Electrical Discharge Machining (EDM) adalah non-conventional machining process. EDM dapat memotong semua jenis benda kerja yang bersifat penghantar listrik, terutama digunakan pada benda kerja yang sangat keras dan memiliki bentuk yang rumit, yang tidak dapat dipotong oleh mesin konvensional. Penelitian ini menggunakan metode Taguchi untuk menentukan variabel pemesinan yang secara signifikan mempengaruhi proses pemotongan pada beberapa material elektroda (tembaga, kuningan, alumunium) dan benda kerja dari bahan K460 (amutit S). Taguchi L25 Orthogonal standard arrays dan analysis of variance (ANOVA) dapat menentukan performa variabel pemotongan (PON, POFF, GAP, QDON, SERVO dan LT) dengan variabel yang diteliti adalah Electrode Wear Rate (EWR), Material Removal Rate (MRR) dan Diameter Overcut (DOC). Hasil dari penelitian ini ditampilkan dalam bentuk tabel-tabel dan grafik yang menunjukan variabel pemesinan yang signifikan mempengaruhi proses pemotongan sesuai dengan jenis material elektroda yang digunakan.

scholarly journals Influence of the Anode Material and the Flushing Gas on the Dry Electrical Discharge Machining Process

2013 ◽  
Vol 7 (5) ◽  
pp. 581-592
Author(s):  
Raoul Roth ◽  
◽  
Beck Lukas ◽  
Hartmi Balzer ◽  
Friedrich Kuster ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Work Piece ◽  
Specific Material ◽  
Environmentally Friendly Process ◽  
Dry Electrical Discharge Machining

In the last years dry electrical discharge machining (DEDM) has been proposed as an alternative to the traditional EDM. The main reason for these efforts is the absence of a liquid dielectric which results in a simpler and environmentally friendly process. This paper presents measurements of the material removal rate in function of different tool electrodes, work piece materials and flushing gases put in relation with the breakdown behavior of the process. Evaluation of absolute and current specific material removal rate are presented. The data show a big influence on the material removal rate depending on the combination of work piece material and flushing gas. Two different effects are observed, the first enhancing the removal per spark and the second one reducing the short circuiting occurrence. The share of these two effects on the enhancing of the absolute material removal rate also differs in function of the work piece material. It is suggested that the chemical reaction strongly influences the process in two different ways, on one hand releasing a surplus of energy and on the other hand changing the debris particles’ properties.

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