Optimization of Wedm Parameters for Surface Roughness on Hybrid Mmcs

2014 ◽  
Vol 23 (3) ◽  
pp. 096369351402300
Author(s):  
D. Satishkumar ◽  
M. Kanthababu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Matrix Composites ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Unconventional Machining ◽  
Central Composite ◽  
Wire Feed

Metals or alloys when reinforced with more than one reinforcement materials are generally considered as hybrid metal matrix composites (MMCs). The superior properties of the hybrid MMCs deter its wide applications due to the difficulty in machining. Wire electrical discharge machining (WEDM) is an effective unconventional machining process which can be used to machine difficult to machine materials. This work is aimed towards optimizing the WEDM parameters to achieve better surface roughness ( Ra) during machining of stir cast unreinforced A17075 alloy and A17075/B4C/Al2O3 based hybrid MMCS. The experiments were carried out as per central composite design of response surface methodology (RSM). It is observed that all the process parameters such as pulse-on time ( TON), pulse-off time ( TOFF), wire feed (F), gap voltage (V) considered in this work were significant.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

scholarly journals Surface Roughness Prediction for Steel 304 In Edm Using Response Graph Modeling

2018 ◽  
Vol 14 (4) ◽  
pp. 115-124 ◽  
Author(s):  
Shukry H. Aghdeab ◽  
Nareen Hafidh Obaeed ◽  
Marwa Qasim Ibraheem
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Applied Current ◽  
Graph Modeling ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technique for metals removing which is relied upon the basic fact that negligible tool force is produced during the machining process. Also, electrical discharge machining is used in manufacturing very hard materials that are electrically conductive. Regarding the electrical discharge machining procedure, the most significant factor of the cutting parameter is the surface roughness (Ra). Conventional try and error method is time consuming as well as high cost. The purpose of the present research is to develop a mathematical model using response graph modeling (RGM). The impact of various parameters such as (current, pulsation on time and pulsation off time) are studied on the surface roughness in the present research. 27 samples were run by using CNC-EDM machine which used for cutting steel 304 with dielectric solution of gas oil by supplied DC current values (10, 20, and 30A). Voltage of (140V) uses to cut 1.7mm thickness of the steel and use the copper electrode. The result from this work is useful to be implemented in industry to reduce the time and cost of Ra prediction. It is observed from response table and response graph that the applied current and pulse on time have the most influence parameters of surface roughness while pulse off time has less influence parameter on it. The supreme and least surface roughness, which is achieved from all the 27 experiments is (4.02 and 2.12µm), respectively. The qualitative assessment reveals that the surface roughness increases as the applied current and pulse on time increases

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

scholarly journals Electrical Discharge Machining with SiC Powder-Mixed Dielectric: An Effective Application in the Machining Process of Hardened 90CrSi Steel

Machines ◽  
2020 ◽  
Vol 8 (3) ◽  
pp. 36 ◽  
Author(s):  
Thi-Hong Tran ◽  
Manh-Cuong Nguyen ◽  
Anh-Tung Luu ◽  
The-Vinh Do ◽  
Thu-Quy Le ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

As a successful solution applied to electrical discharge machining (EDM), powder-mixed electrical discharge machining (PMEDM) has been proposed as an upgrade of the EDM process. The optimization of the process parameters of PMEDM is essential and pressing. In this study, Taguchi methods and analysis of variance (ANOVA) were used to find the main parameters affecting surface roughness in the EDM process with SiC powder-mixed-dielectric of hardened 90CrSi steel. The PMEDM parameters selected were the powder concentration, the pulse-on-time, the pulse-off-time, the pulse current, and the server voltage. It was found that SiC powder exhibits positive effects on reducing surface roughness. The roughness obtained with the optimum powder concentration of 4 g/L was reduced by 30.02% compared to that when processed by conventional EDM. Furthermore, the pulse-off-time was found to be the most influential factor that gave an important effect on surface roughness followed by the powder concentration. The EDM condition including a powder concentration of 4 g/L, a pulse-on-time of 6 µs, a pulse-off-time of 21 µs, a pulse current of 8 A, and a server voltage of 4 V resulted in the best surface roughness.

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.

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.   

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 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.

Effect of Electrical Discharge Machining on Surface Roughness of Cylindrical Shaped Parts

2020 ◽  
Vol 853 ◽  
pp. 13-17
Author(s):  
Le Hong Ky ◽  
Thi Hong Tran ◽  
Nguyen Van Cuong ◽  
Tran Thanh Hoang ◽  
Do Thi Tam ◽  
...  
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Optimum Input

This paper introduces an experimental study on the influence of electrical discharge machining (EDM) cylindrical shaped parts made of 90CrSi tool steel. In this work, some experiments were designed and analysed based on Taguchi method. Also, four input parameters including the pulse on time, the pulse off time, the current, and the server voltage were investigated. The influence of these parameters on the surface roughness were estimated by analysing variance. In addition, the optimum input parameters were found for getting the minimum surface roughness.

scholarly journals Parametric Study for Wire Cut Electrical Discharge Machining of Sintered Titanium

2019 ◽  
Vol 69 (1) ◽  
pp. 17-38 ◽  
Author(s):  
De Dwaipayan ◽  
Nandi Titas ◽  
Bandyopadhyay Asish
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Sintered Titanium ◽  
Wire Tension ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

AbstractIn 21st century, it has been observed that Wire Cut Electrical Discharge Machining (WEDM) has evolved as one of the most important non-traditional machining process. The popularity and its success lies because of its uniqueness towards producing different components which are very difficult to machine like titanium, tungsten carbide, Inconel materials etc and provides a platform in producing intricate complex shape which in many cases become impossible to machine by traditional machining methods. Pure sintered titanium bears very high specific strength, abrasion and corrosion resistances and thus machining this type of materials by conventional techniques becomes very difficult though this material finds immense applications in bio-plant and aerospace components. In the present work, WEDM on pure sintered titanium is studied. The different input parameters of WEDM like, pulse on time, pulse off time, wire tension and wire feed have been varied to investigate the output response like MRR, Surface Roughness (Ra), Kerf Width and Over Cut. A response surface methodology (4 factors 3 level) design of experiment (DOE) has been applied in this context to examine the machining ability of pure sintered titanium and results are found to be satisfactory and verified by confirmatory test. The machining parameters like pulse on time, pulse off time, wire tension and wire feed shows immense effect on the output responses and present study provide an optimal conditions of these input parameters to get the best output responses through RSM

Sign in / Sign up

Export Citation Format

Share Document