Response Surface Approach for Optimization of Sinker Electric Discharge Machine Process Parameters on AISI 4140 Alloy Steel

The purpose of this paper is to determine the optimal factors of the electro-discharge machining (EDM) process investigate feasibility of design of experiment techniques. The work pieces used were rectangular plates of AISI 4140 grade steel alloy. The study of optimized settings of key machining factors like pulse on time, gap voltage, flushing pressure,input current and duty cycle on the material removal,surface roughness is been carried out using central composite design. The output responses measured were material removal rate (MRR) and surface roughness. Mathematical models are proposed for the above responses using response surface methodology (RSM). The results reveals that MRR is more influenced by peak current, duty factor. Finally, the parameters were optimized for maximum MRR with the desired surface roughness

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Optimization of WEDM Process Parameters

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.592-594.831 ◽

2014 ◽

Vol 592-594 ◽

pp. 831-835 ◽

Cited By ~ 1

Author(s):

Vikram Singh ◽

Sharad Kumar Pradhan

Keyword(s):

Surface Roughness ◽

Response Surface ◽

Process Parameters ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Machining Parameters ◽

Pulse On Time ◽

Pulse Off Time ◽

Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

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Tool Wear Rate Prediction by using Optimization Techniques

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.b6416.129219 ◽

2019 ◽

Vol 9 (2) ◽

pp. 1271-1277

Keyword(s):

Surface Roughness ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Optimization Techniques ◽

Machining Process ◽

Machining Parameters ◽

Tungsten Carbides ◽

Electro Discharge Machining ◽

Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

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Effect of Input Parameters on SR and MRR for Tool Steel AISI L2 By Electric Discharge Machine (EDM)

Engineering and Technology Journal ◽

10.30684/etj.v39i6.1849 ◽

2021 ◽

Vol 39 (6) ◽

pp. 928-935

Author(s):

Shukry H. Aghdeab ◽

Raed R. Shwaish ◽

Tahseen M. Salman

Keyword(s):

Surface Roughness ◽

Electric Discharge ◽

Material Removal ◽

Removal Rate ◽

Electric Discharge Machine ◽

Steel Aisi ◽

Discharge Machine ◽

Pulse On Time ◽

Pulse Off Time ◽

Off Time

Electric discharge machine (EDM) or may be call electric spark machine is one of the most important cutting process or manufacturing process because it gives high accurate dimension and can be produced the most complex shape. In this present material removal rate and surface roughness for tool steel AISI L2 studied. The input parametric for this process is current, pulse on time (Ton) and pulse off time (Toff).A full factorial method is used to formulate machine parameters and find the optimal process parameters of an electric spark. The result shows that the Surface roughness increasing with increasing current and pulse on time is increases while no effect by increase in pulse off time. Best surface roughness when using low current and pulse in time. The material removal rate is increasing with increasing in current and pulse on time while decreasing when pulse of time is increased. The experimented and predicted values by using Minilab17 software of this process are approximately equal.

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Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

International Journal of Manufacturing Engineering ◽

10.1155/2014/259129 ◽

2014 ◽

Vol 2014 ◽

pp. 1-16 ◽

Cited By ~ 12

Author(s):

Teepu Sultan ◽

Anish Kumar ◽

Rahul Dev Gupta

Keyword(s):

Surface Roughness ◽

Response Surface Methodology ◽

Wear Rate ◽

Response Surface ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Electrode Wear ◽

Electrode Wear Rate ◽

Pulse On Time

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

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Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Energies ◽

10.3390/en13010038 ◽

2019 ◽

Vol 13 (1) ◽

pp. 38 ◽

Cited By ~ 1

Author(s):

Misbah Niamat ◽

Shoaib Sarfraz ◽

Wasim Ahmad ◽

Essam Shehab ◽

Konstantinos Salonitis

Keyword(s):

Surface Roughness ◽

Wear Rate ◽

Process Parameters ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Electrode Wear ◽

Multi Objective Optimization ◽

Electro Discharge Machining ◽

Pulse On Time

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

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Optimization of EDM Process Parameter for MRR and SR of 17- 4 PH Steel Using Response Surface Methodology

Transportation Management ◽

10.24294/tm.v1i2.633 ◽

2018 ◽

Vol 1 (2) ◽

Author(s):

SHUBHRATA NAGPAL

Keyword(s):

Surface Roughness ◽

Response Surface Methodology ◽

Response Surface ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Optimization Techniques ◽

Pulse On Time

In the present work, an attempt has been made for material removal rate and surface roughness by response surface optimization techniques in Electrical discharge machining. Electrical discharge machining, commonly known as EDM, is a process that is used to remove metal through the action of an electrical discharge of short duration and high current density between the work piece and too. This work presents the results of a mathematical investigation carried out to the effects of machining parameters such as current, pulse on time, pulse off time and lift time on material removal rate and surface roughness in electrical discharge machining of 17-4 PH steel by using copper electrode. Response surface methodology and ANOVA techniques are used for data analysis to solve the multi-response optimization. To validate the optimum levels of the parameter, confirmation run was performed by setting the parameters at optimum levels. Material Removal Rate during the process has been taken as productivity estimate with the objective to maximize it. With an intention of minimizing surface roughness is been considered as most important output parameter. It is found that the good agreement of that current is most significant parameter for material removal rate and less for surface roughness followed by pulse on time and lift time.

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Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

Engineering and Technology Journal ◽

10.30684/etj.v38i9a.1549 ◽

2020 ◽

Vol 38 (9A) ◽

pp. 1352-1358

Author(s):

Saad K. Shather ◽

Abbas A. Ibrahim ◽

Zainab H. Mohsein ◽

Omar H. Hassoon

Keyword(s):

Surface Roughness ◽

Material Removal Rate ◽

Material Removal ◽

High Speed ◽

Composite Electrode ◽

Removal Rate ◽

Pure Copper ◽

High Speed Steel ◽

Pulse On Time ◽

Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

Open Engineering ◽

10.1515/eng-2020-0049 ◽

2020 ◽

Vol 10 (1) ◽

pp. 401-407

Author(s):

Yanuar Rohmat Aji Pradana ◽

Aldi Ferara ◽

Aminnudin Aminnudin ◽

Wahono Wahono ◽

Jason Shian-Ching Jang

Keyword(s):

Surface Roughness ◽

Metallic Glasses ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Surface Hardness ◽

Recast Layer ◽

Surface Evaporation ◽

Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

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