Effect of process parameters on material removal rate and surface roughness in electric discharge drilling of Inconel 718 using graphite electrode

2011 ◽  
Vol 23 (3/4) ◽  
pp. 214 ◽  
Author(s):  
P. Kuppan ◽  
S. Narayanan ◽  
A. Rajadurai
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Inconel 718 ◽  
Material Removal ◽  
Graphite Electrode ◽  
Removal Rate

scholarly journals Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3689
Author(s):  
Thanikodi Sathish ◽  
Vinayagam Mohanavel ◽  
Khalid Ansari ◽  
Rathinasamy Saravanan ◽  
Alagar Karthick ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Stir Casting ◽  
Electric Discharge Machining ◽  
Az61 Magnesium Alloy

Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.

Optimization of Process Parameters in Plasma Arc Cutting Applying Genetic Algorithm and Fuzzy Logic

2018 ◽  
pp. 123-139
Author(s):  
Nehal Dash ◽  
Apurba Kumar Roy ◽  
Sanghamitra Debta ◽  
Kaushik Kumar
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Fuzzy Logic ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Plasma Arc ◽  
Plasma Arc Cutting ◽  
Optimization Of Process Parameters

Plasma Arc Cutting (PAC) process is a widely used machining process in several fabrication, construction and repair work applications. Considering gas pressure, arc current and torch height as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness would be considered as factors that determines the quality, machining time and machining cost. In order to reduce the number of experiments Design of Experiments (DOE) would be carried out. In later stages applications of Genetic Algorithm (GA) and Fuzzy Logic would be used for Optimization of process parameters in Plasma Arc Cutting (PAC). The output obtained would be minimized and maximized for Surface Roughness and Material Removal Rate respectively using Genetic Algorithm (GA) and Fuzzy Logic.

Multi Response Optimization of Process Parameters of Abrasive Water Jet Machining for Stainless Steel AISI 304 Using VIKOR Approach Coupled with Signal to Noise Ratio Methodology

2015 ◽  
Vol 14 (02) ◽  
pp. 107-121 ◽  
Author(s):  
Vedansh Chaturvedi ◽  
Diksha Singh
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Aisi 304 ◽  
Steel Aisi ◽  
Machining Characteristics ◽  
Stainless Steel Aisi ◽  
Experimental Runs

As the population of the world is continuously increasing, demand of the mechanical manufactured products is also increasing. Machining is the most important process in any mechanical manufacturing, and in machining two factors, i.e. material removal rate (MRR) and surface roughness (SR) are the most important responses. If the MRR is high, the product will get desired shape in minimum time so the production rate will be high, but we could not scarify with the surface finishing also because in close tolerance limit parts like in automobile industry, if the surface is rough exact fit cannot take place. The term optimization is intensively related to the field of quality engineering. Abrasive water jet machining is an important unconventional machining, in order to obtain better response, i.e. material removal rate and surface roughness. Various process parameters of AWJM need to be observed and selected to improve machining characteristics. Better machining characteristics can be achieved by optimizing various process parameters of AWJM. This study considers four process control parameters such as transverse speed, standoff distance, abrasive flow rate and water pressure. The response is taken to be material removal rate and surface roughness. The work piece for stainless steel AISI 304 material of size 15 cm × 10 cm × 2 cm is selected for experiments. Sixteen experimental runs (two trials for each experimental runs) were carried out for calculating MRR and SR and average value of these two trials have been taken for analysis. MRR is normalized according to higher-is-better and SR is normalized according to lower is better. The experiment data analysis is done and VIKOR index is found. Finally, the analysis of VIKOR index using S/N ratio is done and found the most significant factor for AWJM and predicted optimal parameters setting for higher material removal rate and lower surface roughness. Verification of the improvement in quality characteristics has been made through confirmation test with the predicted optimal parameters setting. It is found that the determined optimum combination of AWJM parameters gives the lowest VIKOR INDEX which shows the successful implementation of VIKOR Method coupled with S/N ratio in AWJM.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

2011 ◽  
Vol 189-193 ◽  
pp. 1393-1400 ◽  
Author(s):  
M.M. Rahman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
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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