scholarly journals Parametric optimization of wire cut electrical discharge machining

2014 ◽  
Vol 3 (2) ◽  
pp. 212
Author(s):  
M. Durairaj ◽  
A.K.S. Ansari ◽  
M. H. Gauthamkumar
Keyword(s):  
Surface Roughness ◽  
Orthogonal Array ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Fluid Pressure ◽  
Performance Criteria ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

Optimization of machining parameters in chromium-additive mixed electrical discharge machining of the AA7075/5%B4C composite

2021 ◽  
pp. 095440892110317
Author(s):  
Vineet Dubey ◽  
Anuj K Sharma ◽  
Balbir Singh
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Process Condition ◽  
Dielectric Fluid ◽  
Optimum Process ◽  
Machining Parameters ◽  
Machined Surface ◽  
Pulse On Time ◽  
Pulse Off Time

The present study establishes the optimum process condition for additive mixed electrical discharge machining of Al7075–5%B4Cp metal matrix composite by performing experimental investigation. The suspension of chromium particles in a dielectric fluid is used as an additive. The input process parameters selected for experimentation are specifically pulse on-time, gap voltage, pulse off-time and peak current, for analysing their influence on wear of the tool along with surface roughness of the composite. Comparative study of the machined surface is done by analysing microstructures, cracks and recast layers formed at different settings of input parameters using a scanning electron microscope. Rise in amount of current and pulse on-time led to increased height of the recast layer generated on the surface of the machined workpiece. Furthermore, a confirmatory experiment was performed at the optimal setting. The result revealed an error of 5.5% and 7.5% between experimental and predicted value of tool wear rate and surface roughness.

Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire

2014 ◽  
Vol 592-594 ◽  
pp. 416-420 ◽  
Author(s):  
Singaravelu D. Lenin ◽  
A. Uthirapathi ◽  
Ramana Reddy P.S. Venkata ◽  
Muthukannan Durai Selvam
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Brass Wire

The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

scholarly journals Performance evaluation of wire electrical discharge machining on Titanium Alloy

2018 ◽  
Vol 1 (1) ◽  
pp. 27-38
Author(s):  
Jun Qi Tan ◽  
Mohd Yazid Abu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter

The experimental carried out to aim at the selection of the best condition machining parameter combination for wire electrical discharge machining (WEDM) of titanium alloy (Ti–6Al–4V). By using Design Expert 10 software, a series of experiments were performed by selecting pulse-on time, pulse-off time, servo voltage and peak current as parameters. The responses that considered were cutting speed, material removal rate, sparking gap and surface roughness. Based on ANOVA analysis, the effect from the parameters on the responses was determined. The optimum machining parameters setting for the maximum cutting speed, minimum sparking gap and minimum surface roughness were found by proceed optimization experiment. Then, each optimization response had their own combination setting on WEDM to cut titanium alloy. 3D response surface graph such as dome and bowl shape represent maximum and minimum point for the solutions had shown in the report. Finally, predicted and actual value from the experiment have been calculated for validation.

Analysis of Effects of Machining Parameters on Surface Roughness in Electrical Discharge Machining Tablet Shape Punches Using Taguchi Method

2020 ◽  
Vol 977 ◽  
pp. 12-17
Author(s):  
Thi Hong Tran ◽  
Tien Dung Hoang ◽  
Hong Ky Le ◽  
Thi Tam Do ◽  
Thanh Hien Bui ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Machining Parameters ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents a study on analysis of influences of the surface roughness in Electrical Discharge Machining 90CrSi tablet shape punches with the use of copper electrode. In this paper, 9 experimental runs were designed and conducted by using Taguchi method. In addition, 4 process parameters including the gap voltage, the pulse current, the pulse on time and the pulse off time were investigated. The influences of these input parameters on the surface roughness were evaluated by analysing variance. Also, from the experimental results, optimum values of the input parameters for getting the minimum surface roughness were proposed.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

Surface Roughness at Wire Electrical Discharge Machining

2015 ◽  
Vol 760 ◽  
pp. 551-556 ◽  
Author(s):  
Oana Dodun ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Vasile Merticaru ◽  
Gheorghe Nagîţ
Keyword(s):  
Surface Roughness ◽  
Empirical Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Wire Electrical Discharge Machining ◽  
Power Type ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining is a machining method by which parts having various contours could be detached from plate workpieces. The method uses the electrical discharges developed between the workpiece and the wire tool electrode found in an axial motion, when in the work zone a dielectric fluid is recirculated. In order to highlight the influence exerted by some input process factors on the surface roughness parameter Ra in case of a workpiece made of an alloyed steel, a factorial experiment with six independent variables at two variation levels was designed and materialized. As input factors, one used the workpiece thickness, pulse on time, pulse off-time, wire axial tensile force, current intensity average amplitude defined by setting button position and travelling wire electrode speed. By mathematical processing of the experimental results, empirical models were established. Om the base of a power type empirical model, graphical representations aiming to highlight the influence of some input factors on the surface roughness parameter Ra were achieved. The power type empirical model facilitated establishing of order of factors able to exert influence on the surface roughness parameter Ra at wire electrical discharge machining.

scholarly journals Analysis, predictive modelling and multi-response optimization in electrical discharge machining of Al-22%SiC metal matrix composite for minimization of surface roughness and hole overcut

2020 ◽  
Vol 7 ◽  
pp. 20 ◽  
Author(s):  
Subhashree Naik ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Discharge Current ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Response Optimization ◽  
Pulse On Time

Due to the widespread engineering applications of metal matrix composites especially in automotive, aerospace, military, and electricity industries; the achievement of desired shape and contour of the machined end product with intricate geometry and dimensions that are very challenging task. This experimental investigation deals with electrical discharge machining of newly engineered metal matrix composite of aluminum reinforced with 22 wt.% of silicon carbide particles (Al-22%SiC MMC) using a brass electrode to analyze the machined part quality concerning surface roughness and overcut. Forty-six sets of experimental trials are conducted by considering five machining parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken's design of experiments (BBDOEs). This article demonstrates the methodology for predictive modeling and multi-response optimization of machining accuracy and surface quality to enhance the hole quality in Al-SiC based MMC, employing response surface methodology (RSM) and desirability function approach (DFA). Finally, a novel approach has been proposed for economic analysis which estimated the total machining cost per part of rupees 211.08 during EDM of Al-SiC MMC under optimum machining conditions. Thereafter, under the influence of discharge current several observations are performed on machined surface morphology and hole characteristics by scanning electron microscope to establish the process. The result shows that discharge current has the significant contribution (38.16% for Ra, 37.12% in case of OC) in degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The machining data generated for the Al-SiC MMC will be useful for the industry.

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

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

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