A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

2021 ◽  
pp. 251659842110633
Author(s):  
Suresh Gudipudi ◽  
Selvaraj Nagamuthu ◽  
Kanmani Subbu Subbian ◽  
Surya Prakasa Rao Chilakalapalli
Keyword(s):  
Surface Integrity ◽  
Discharge Current ◽  
Material Removal ◽  
Removal Rate ◽  
Principal Component ◽  
Dimensional Accuracy ◽  
Local Optimum ◽  
Machined Surface ◽  
Input Parameters ◽  
Grey Relation

In electro-discharge machining (EDM), the material removal takes place by precisely controlled sparks that occur between tool and workpiece separated with a spark gap in the presence of a dielectric. Generally, the non-contacting type and less material removal rates are attributed to attain a good surface finish and close dimensional tolerances during an EDM of monolithic metals and alloys. But the dimensional accuracy and surface integrity parameters would considerably affect during EDM of composites due to the existence of more than one material phase constituents. Therefore, the present work aims to study and optimize the performance characteristics under various EDM conditions employed in making rectangular channels on AA6061-B4C composite material. Initially, AA6061-4wt.%B4C composites were fabricated by ultrasonically assisted stir-casting, and the improved properties were obtained from various mechanical characterizations. The EDM experiments were conducted according to the full factorial experimental design. The three levels of input conditions such as discharge Current (I), discharge duration (T On), and discharge idle time (T Off) were considered. The considered output responses are material removal rate (MRR),taper (θ) of the machined channel, tool wear rate (TWR), average surface roughness (R) of the machined surface, and average recast layer thickness (ARLT) of the machined zone. These responses are co-related with multi-objective types in the sense that the MRR has to be maximized with all other responses minimized. Hence, principal component analysis (PCA) coupled with grey relation analysis (GRA) was used for optimization in which the results were normalized, and all the responses were converted into a single response named weighted grey relation grade (WGRG) for each trial. The experimental trial, which had the highest WGRG, was considered as a local optimum. The global optimum parameters were obtained by performing the Taguchi method (TM) (higher-the-better) for the maximization of WGRG. The analysis of variance (ANOVA) was performed to know the contribution of each EDM parameter toward the WGRG. The optimum levels of Current, T On, and T Off were identified as 8 A, 25 µs, and 36 µs, respectively. Results showed that all three input parameters significantly affected the WGRG, and a higher contribution of Current (52.11%) followed by the T On (26.72%) was observed. The interaction between the Current and T Off was found to be greater than other interactions. Taper values were observed to be reduced at the combination of 8 A discharge Current and 25 µs T On. None of the input parameters significantly affected the Ra, except for Current, which showed a slight effect. ARLT values showed an increasing trend of T On from 25 µs to 45 µs but decreased slightly at 65 µs for all Current levels. The moderate Current level 6 A was observed to be favorable in reducing ARLT when compared to low (4 A) and high (8 A) for all Ton values.

Single Discharge Finite Element Simulation of EDM Process

2015 ◽  
Vol 14 (02) ◽  
pp. 75-89 ◽  
Author(s):  
Rohit Rajendran ◽  
S. P. Vendan
Keyword(s):  
Finite Element ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Workpiece Material ◽  
Machined Surface ◽  
Input Parameters ◽  
Pulse On Time ◽  
Aisi H13 Tool Steel

The energy distribution in the electric discharge machining process influences the material removal rate, relative wear ratio and the surface roughness of the machined surface and the effective energy is the part of energy which is distributed toward workpiece to be machined. The theoretical modeling of the process is based upon the heat transfer equations and one of the important parameter is fraction of energy transferred to the workpiece. The model first calculates the temperature distribution in the workpiece material using ANSYS Finite element coding and then volume removed due to single spark is estimated from the temperature profiles. Theoretical material removal rate at different input parameters are compared with the experimental results, making it possible to determine the portion of energy that enters AISI H13 tool steel workpiece. The effect of input parameters (discharge current, voltage, pulse on time) on temperature distributions along the radius and depth of the workpiece has been reported.

EDM with USM Combination Process of Sintered NdFeB Permanent Magnet

2010 ◽  
Vol 44-47 ◽  
pp. 1066-1069
Author(s):  
Li Li ◽  
Li Ling Qi ◽  
Zong Wei Niu
Keyword(s):  
Permanent Magnet ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Dielectric Fluid ◽  
Machined Surface ◽  
Combination Process ◽  
Electro Discharge Machining ◽  
Ndfeb Permanent Magnet ◽  
Machining Characteristics

This paper presents an experimental investigation of the machining characteristics of sintered NdFeB permanent magnet using a combination process of electro-discharge machining (EDM) with ultrasonic machining (USM). Concentration of abrasive in the dielectric fluid is changed to explore its effect on the material removal rate (MRR). MRR of EDM /USM, conventional EDM are compared, machined surface characteristics are also compared between them. It is concluded that the combination EDM/USM process can increase the MRR and decrease the thickness of the recast layer. In the combination process, an appropriate abrasive concentration can improve its machining efficiency.

Optimization of process parameters of powder mixed EDM for high carbon high chromium alloy steel (D2 steel) through GRA approach

2018 ◽  
Vol 8 (4) ◽  
pp. 388-398 ◽  
Author(s):  
Kanwal Jit Singh
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Chromium Alloy ◽  
High Carbon ◽  
Content Type ◽  
Practical Applications ◽  
Relational Analysis ◽  
Input Parameters ◽  
Grey Relational ◽  
D2 Steel

Purpose The purpose of this paper is to investigate the process parameters and optimise the machining input parameter of powder mixed electric discharge machining for high carbon high chromium alloy steel (D2 steel) for the industrial application. Grey relational analysis approach has been used to obtain the multiple performance output response. Design/methodology/approach In this experimental work, input parameters, namely, pulse on-time, discharge current, tool material and grit size, are selected. The design of the experiment has been constructed with the help of MINITAB 7 Software, in which L16 orthogonal array has been preferred for the experimentation. The effect of input parameters, namely, material removal rate, tool wear rate and surface roughness, is investigated. Grey relational analysis and analysis of variance are performed to optimise the input parameters and better output results. Findings In this experimentation, there is an increment of tool wear rate by 64.49 per cent, material removal rate by 47.14 per cent and surface roughness by 35.82 per cent. Practical implications A lot of practical applications have been found in many different material processing industries like metallurgy, machinery, electronics, transportation, military science, agricultural machinery, etc. These practical applications have brought forward definite and noticeable economic benefits. Originality/value The reader is given a general overview on the machining investigation and optimisation of processes parameters through the grey theory approach. It gives a new framework to investigate the problems where multiple input machining variable and various output responses are obtained in single optimised parameters.

Grinding-aided electrochemical discharge drilling in the light of electrochemistry

2018 ◽  
Vol 233 (6) ◽  
pp. 1896-1909 ◽  
Author(s):  
VG Ladeesh ◽  
R Manu
Keyword(s):  
Material Removal Rate ◽  
Borosilicate Glass ◽  
Chemical Etching ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Hybrid Technique ◽  
Machined Surface ◽  
Influence Of Process Parameters ◽  
Electrochemical Discharge

The electrically non-conductive materials like glass, ceramics, quartz, etc. are of great interest for many applications in modern industries. Machining them with high quality and at a faster rate is a challenging task. In this study, a novel technique called grinding aided electrochemical discharge drilling (G-ECDD) is demonstrated which uses a hollow diamond core drill as the tool for performing electrochemical discharge machining of borosilicate glass. The new hybrid technique enhances the material removal rate and machining accuracy to several folds by combining the thermal melting action of discharges and grinding action of the abrasive tool. This paper presents the experimental investigation on the material removal rate during G-ECDD of glass while using different electrolytes. An attempt has been made to explore the influence of electrolyte temperature on G-ECDD performance by maintaining the electrolyte at different temperatures. Experiments were conducted using three different electrolytes which include NaOH, KOH, and the mixture of both. The results obtained from this study revealed that an increase in temperature will favor chemical etching as well as electrochemical reaction rate. Also, it was observed that heating the electrolyte leads to an increase in the bubble density and enhances the ion mobility. This causes the formation of gas film at a faster rate and thereby improving the discharge activity. Thus, machining will be done at a faster rate. Better results are obtained while using a mixture of NaOH and KOH. From the microscopic images of the machined surface, it was observed that material removal mechanism in G-ECDD is a combination of grinding action, electrochemical discharges, and chemical etching. Response surface methodology was adopted for studying the influence of process parameters on the performance of G-ECDD. The new technique of grinding aided electrochemical discharge drilling proved its potential to machine borosilicate glass and simultaneously offers good material removal rate, repeatability, and accuracy.

scholarly journals An Experimental Study on the Precision Abrasive Machining Process of Hard and Brittle Materials with Ultraviolet-Resin Bond Diamond Abrasive Tools

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 125 ◽  
Author(s):  
Lei Guo ◽  
Xinrong Zhang ◽  
Shibin Chen ◽  
Jizhuang Hui
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Manufacturing Process ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Ultraviolet Curable

Ultraviolet-curable resin was introduced as a bonding agent into the fabrication process of precision abrasive machining tools in this study, aiming to deliver a rapid, flexible, economical, and environment-friendly additive manufacturing process to replace the hot press and sintering process with thermal-curable resin. A laboratory manufacturing process was established to develop an ultraviolet-curable resin bond diamond lapping plate, the machining performance of which on the ceramic workpiece was examined through a series of comparative experiments with slurry-based iron plate lapping. The machined surface roughness and weight loss of the workpieces were periodically recorded to evaluate the surface finish quality and the material removal rate. The promising results in terms of a 12% improvement in surface roughness and 25% reduction in material removal rate were obtained from the ultraviolet-curable resin plate-involved lapping process. A summarized hypothesis was drawn to describe the dynamically-balanced state of the hybrid precision abrasive machining process integrated both the two-body and three-body abrasion mode.

OPTIMASI PARAMETER PEMESINAN WIRE ELECTRIC DISCHARGE MACHINING BAJA PERKAKAS SKD 11 MENGGUNAKAN METODE TAGUCHI

ROTOR ◽  
2018 ◽  
Vol 11 (2) ◽  
pp. 33
Author(s):  
Setiawan Okik Aris ◽  
Djumhariyanto Dwi ◽  
Mulyadi Santoso
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Manufacturing Industry ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Current Strength ◽  
Influential Factor ◽  
Hard Material ◽  
Taguchi Optimization ◽  
The Wire

EDM wire is one of the non-conventional machinings that is currently widely used in the manufacturing industry because it can process workpieces with hard material and also produces excellent dimensional accuracy. This research was carried out with variable current, voltage and wire speed processes. While the response variable is the material removal rate and cutting width (kerf), this study aims to determine the effect of each factor on each response as well as on the combined response and to find the right combination of parameters to produce optimal response values. The results of the study stated that the current strong factor contributed 89.84% and the wire speed factor was 8.26% against the cutting width response (kerf). The current strong element contributes 87.88% to the material removal rate response. As for the combined response, the influential factor was wire speed with a contribution of 92.79%. The optimal combination of parameters in the combined response is 7 amperes, 5 volts and 10 m / s wire speed. The conclusion of this study informs that the smaller the current strength, the better the value of the cutting width, while the more significant the current force will result in a higher removal rate material. The factor that influences the combined response is wire speed, where the increase in the value of the wire speed increases the amount of the Gray Relational Grade from the combined response. Keywords: Wire EDM, SKD 11 Steel, Taguchi, Optimization

Parametric Optimization of EN-31 Steel in Wire Cut Electro Discharge Machining by Taguchi Technique

2020 ◽  
Vol 12 (7) ◽  
pp. 881-887
Author(s):  
Sahil Sharma ◽  
Umesh Kumar Vates ◽  
Amit Bansal
Keyword(s):  
Material Removal Rate ◽  
Automobile Industry ◽  
Material Removal ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Work Piece ◽  
Electro Discharge Machining ◽  
En 31 ◽  
The Impact ◽  
Dies And Moulds

Amongst the various methods of machining, Electro Discharge Machining is the convenient alternatives for the industries due to non-contact of work piece and tool. In the study of various EDM processes the main target is to achieve the better finish of surface, high material removal rate and good dimensional accuracy by regulating the different input parameters. There are various applications of EDM such as aerospace parts, medical equipments, dies and moulds, nuclear and automobile industry. In this experimental study, a trial has made to look the impact of input factors like pulse-on, pulse-off, peak current, tension of wire on rate of material removal, gap current and time for machining. Taguchi (L9 OA) and Analysis of Variance technique were used to optimize the outcomes for wire cut EDM of EN-31 tool steel. The outcomes revealed that Ton and Toff are the leading cogent factor for material removal rate and gap current respectively.

Investigation of Process Performances and Cut Surface Characteristics in the Wire-EDMing of Silicon

2013 ◽  
Vol 845 ◽  
pp. 950-954 ◽  
Author(s):  
J. Punturat ◽  
Viboon Tangwarodomnukun ◽  
Chaiya Dumkum
Keyword(s):  
Silicon Wafer ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Machined Surface ◽  
The Wire ◽  
P Type ◽  
Cut Surface ◽  
Rough Cut

Wire-EDMing process has been more accepted for cutting and slicing silicon wafer as it can provide a cut with less crack and chipping due to low effect of mechanical stresses. In order to provide a deep analysis of the process, the wire-EDMing performances and cut surface characteristics of p-type (100) monocrystalline silicon wafer have been experimentally investigated in this study. The results have shown that wide kerf width, high material removal rate, large electrode wear and rough cut surface can be obtained under the condition of high open voltage and rough cutting mode. Some micrographs of cut surface morphology have been also reported and discussed, where many craters and small holes can be apparently seen on the machined surface.

scholarly journals Experimental investigation and optimization of wall deflection and material removal rate in milling thin-wall parts

2021 ◽  
Vol 8 ◽  
pp. 17
Author(s):  
Gururaj Bolar ◽  
Shrikrishna Nandkishor Joshi
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Wall Deflection ◽  
Radial Depth ◽  
Tool Diameter

The selection of optimal process parameters is essential while machining thin-wall parts since it influences the quality of the product and affects productivity. Dimensional accuracy affects the product quality, whereas the material removal rate alters the process productivity. Therefore, the study investigated the effect of tool diameter, feed per tooth, axial and radial depth of cut on wall deflection, and material removal rate. The selected process parameters were found to significantly influence the in-process deflection and thickness deviation due to the generation of unfavorable cutting forces. Further, an increase in the material removal rate resulted in chatter, thus adversely affecting the surface quality during the final stages of machining. Considering the conflicting nature of the two performance measures, Non-dominated Sorting Genetic Algorithm-II was adopted to solve the multi-objective optimization problem. The developed model could predict the optimal combination of process variables needed to lower the in-process wall deflection and maintain a superior surface finish while maintaining a steady material removal rate.

scholarly journals EFFECT OF PROCESS PARAMETERS FOR OPTIMUM MATERIAL REMOVAL RATE OF CYLINDRICAL GRINDING OF AISI 1045 STEEL

2015 ◽  
Vol 44 (2) ◽  
pp. 100-104
Author(s):  
Taranveer Singh ◽  
Khushdeep Goyal ◽  
Parlad Kumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Wheel Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Input Parameters ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Number Of Passes

In this experimental work, the effect of various input parameters viz. work speed, wheel speed,abrasive material, depth of cut, concentration of cutting fluid and number of passes has been studied on thematerial removal rate of cylindrical grinded AISI. For experimentation, three levels of each variable have beenselected except wheel speed. Two levels of wheel speed have been taken. Heat treated AISI 1045 has beenconsidered as work piece material. The result reveals that number of passes followed by the type of abrasivematerial is the most significant to influence material removal rate. The optimum set of input parameters formaximizing the material removal rate has also been found.

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