scholarly journals Effect of sintered electrode on microhardness and microstructure in electro discharge deposition of magnesium alloy

2020 ◽  
Vol 29 (1) ◽  
pp. 69-76
Author(s):  
U. Elaiyarasan ◽  
V. Satheeshkumar ◽  
C. Senthilkumar
Keyword(s):  
Magnesium Alloy ◽  
Discharge Current ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Material Migration ◽  
Microhardness And Microstructure ◽  
Influence Parameter ◽  
Load Discharge ◽  
Pulse On Time ◽  
Sintered Electrode

AbstractIn this study, an endeavour have been made to depositing the electrode materials over the surface of the magnesium alloy using electrical discharge machining (EDM) with WC-Cu powder compacted sintered electrode. Various process parameters such as compaction load, discharge current and pulse on time are selected to carry out the experiment in order to attain the maximum material migration rate (MMR) or deposition rate and microhardness (MH). It was concluded that the MMR and MH increased with increase in discharge current and pulse on time at low compacted electrode but it is decreased at lower discharge current and pulse on time. Highest MMR and MH were attained successfully at partial sintered low compaction load electrode. Microstructure evaluation has been carried out on deposited surface using scanning electron microscopy (SEM) and presence of electrode element in the deposited surface was confirmed by energy dispersive spectroscopy (EDS). Defects mechanism such as globules and craters are formed during EDC with high current and pulse on time respectively, which diminishes the surface roughness. It was observed that the compaction load is the influence parameter on the MMR and MH.

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 Modification by EDM Using Co-Cr Sintered Powder Metallurgy Electrode

2012 ◽  
Vol 576 ◽  
pp. 56-59 ◽  
Author(s):  
Ahsan Ali Khan ◽  
Mohammed Baba Ndaliman ◽  
Mohammad Yeakub Ali ◽  
Mas Hafizah Bt Mansor ◽  
Nurul Ain Bt Idrus
Keyword(s):  
Powder Metallurgy ◽  
Mild Steel ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Surface Hardness ◽  
Surface Characteristics ◽  
Dielectric Fluid ◽  
Pulse Interval ◽  
Spectroscopy Analysis ◽  
Sintered Electrode

In this investigation, the powder metallurgy (PM) electrode developed from cobalt (Co) and chromium (Cr) powders was used in electrical discharge machining (EDM). This new Co-Cr sintered electrode was used to machine mild steel workpiece with kerosene dielectric fluid. The main objective is to modify its surface characteristics and secure increased surface hardness. The EDM variables of peak current, pulse duration and pulse interval were applied to investigate these surface properties. Scanning electron microscopy (SEM) / energy dispersive X-ray (EDX) spectroscopy analysis confirmed migration of electrode materials (Co and Cr) onto the EDMed surface. Improved hardness was obtained on the mild steel, the highest being 85.3 HRB. Thus, the Co-Cr electrode introduced into the EDM has the capability of modifying the mild steel surface.

Influence of Electrode Cooling on Material Migration among the Electrodes during EDM of Titanium Alloy

2011 ◽  
Vol 264-265 ◽  
pp. 1199-1204 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Liquid Nitrogen ◽  
Electrical Discharge Machining ◽  
Electrically Conductive ◽  
Workpiece Surface ◽  
Hard Metals ◽  
Material Migration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Dies And Moulds

Electrical discharge machining (EDM) is widely used in the machining of electrically conductive hard metals for the production of dies and moulds. This paper describes an investigation of the effect of electrode cooling on the amount of elements migration from the electrode to the workpiece surface and from the workpiece to the electrode surface. In the present study EDM has been performed with electrodes cooled by liquid nitrogen as well as with electrodes without cooling. Current, pulse-on time, pulse-off time and voltage were taken as the variables during conducting the experiments. The analysis on material migration during EDM was carried out by SEM and EDX. It was observed that EDM with liquid nitrogen reduces material migration and minimizes the surface contamination of both the electrodes.

Effect of Process Parameters in Electric Discharge Machining of Ti-6Al–4V Alloy by Three Different Tool Electrode Materials

2012 ◽  
Vol 488-489 ◽  
pp. 876-880 ◽  
Author(s):  
Manoj Kumar Kuttuboina ◽  
A. Uthirapathi ◽  
Singaravelu D. Lenin
Keyword(s):  
Process Parameters ◽  
Electrode Material ◽  
Electrode Materials ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Good Surface ◽  
Pulse On Time

The effect of process parameters namely peak current, pulse on time and flushing pressure on electrical discharge machining (EDM) of titanium alloy (Ti–6Al–4V) were investigated by using three different tool electrode materials namely copper, brass, and aluminium. Kerosene is used as dielectric. The process parameters for machining Ti6Al4V are varied at three levels by using Taguchi's orthogonal array table. The responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) are measured and the most significant parameter was confirmed by ANOVA (Analysis Of Variance). The test result shows that copper electrode material possesses higher MRR, less TWR as compared to brass and aluminium. Brass and copper tools has good surface finish as compared with aluminium. The finest electrode material for machining of Ti6Al4V alpha beta alloy in EDM process was in the order of copper, brass and aluminium.

Effects of hybrid Al2O3- SiO2 nanoparticles in deionized water on the removal rate and surface roughness during electrical discharge machining of Ti-6Al-4V

2021 ◽  
pp. 095440892110593
Author(s):  
Saeed Oskueyan ◽  
Vahid Abedini ◽  
Alireza Hajialimohamadi
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Silicon Oxide ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Sio2 Nanoparticles ◽  
Deionized Water ◽  
Relative Composition ◽  
Maximum Value ◽  
Pulse On Time

Nowadays, special attention is paid to the application of nanoparticles to improve the performance of Electrical Discharge Machining (EDM). In this paper, modeling and optimizing the process parameters of Nanopowder Mixed Electrical Discharge Machining (NPMEDM) is studied. In this study, the effect of aluminum oxide (Al2O3) and silicon oxide (SiO2) nanoparticles on the deionized water dielectric is investigated simultaneously in the process of electrical discharge machining of Ti-6Al-4V alloy. After analyzing the parameters, the discharge current, concentration, pulse on time, and relative composition are considered as input factors. Response Surface Methodology (RSM) using Design-Expert software is employed for the design of the experiments, analysis of the results, and optimization of the parameters. The results show that the best surface morphology is obtained by machining with the addition of nanoparticles in the relative composition of 50%. In this percentage of the composition, the surface of the workpiece has the least value of crack and recast layer. In addition, the maximum value of the material removal rate (MRR) and minimum value of tool wear rate (TWR) can be achieved in the discharge current of 12 A, pulse on-time of 100 μs, and relative composition of 75% Al2O3 – 25% SiO2.

Analysis of the electrical discharge machining (EDM) performance on Ramor 550 armor steel

2020 ◽  
Vol 62 (5) ◽  
pp. 481-491
Author(s):  
Engin Nas
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Processing Parameters ◽  
Depth Of Cut ◽  
Armor Steel ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Abstract This study investigated the electrical discharge machining (EDM) performance of Ramor 500 Armor steel, a material used in the defense industry for armor production. In addition, the surface quality and amount of material wear of the treated surfaces were determined using different electrical discharge processing parameters for a copper electrode including pulse on-time (99, 150, 225, 300, 351 μs), pulse off-time (10, 15, 23, 30, 35 μs), and discharge current (3, 4, 6, 8, 9 A), at a constant pressure of 1 mm depth of cut. As a result of the experiments, the values related to the material removal rate (MRR) and the surface roughness (Ra) were obtained and the findings analyzed via response surface methodology (RSM). The increase in amperage and pulse on time resulted in an increase in Ra and MRR values. The minimum and maximum Ra and MRR values emerged at currents of 3 and 9 A, respectively. In the experiments performed applying currents of between 3 and 9 A, the white layer widths were measured as 0.0474 mm and 0.0915 mm, respectively. The statistical test results showed that the most effective processing parameters for the MRR were the discharge current amperage (49.01 %) and the pulse off-time (16.51 %), whereas the most effective parameter for the Ra value was the discharge current amperage (79.07 %).

scholarly journals Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis

Micromachines ◽  
2020 ◽  
Vol 11 (5) ◽  
pp. 469 ◽  
Author(s):  
Mustafa Saleh ◽  
Saqib Anwar ◽  
Abdualziz El-Tamimi ◽  
Muneer Khan Mohammed ◽  
Shafiq Ahmad
Keyword(s):  
Surface Morphology ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Cross Sectional ◽  
Microhardness And Microstructure ◽  
Monel 400 ◽  
The One ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

This paper presents the results of an investigation on the capacity of wire electrical discharge machining (WEDM) to produce microchannels in the Nickel-based alloy, Monel 400. The main objective of the current study is to produce microchannels with desired/target geometry and acceptable surface quality. Square cross-sectional microchannels with dimensions of 500 × 500 µm were investigated. Experiments were conducted based on the one-factor-at-a-time approach for the key input WEDM process parameters, namely pulse-on time (TON), pulse-off time (TOFF), average gap voltage (VGAP), wire feed (WF), and dielectric flow rate (FR). Dimensional accuracy, machining speed, surface roughness, surface morphology, microhardness, and microstructure were analyzed to evaluate the microchannels. The minimum errors of 6% and 3% were observed in the width and depth of the microchannels, respectively. Furthermore, microchannels with enhanced surface integrity could be produced exhibiting smooth surface morphology and shallow recast layer (~0–2.55 µm).

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

2021 ◽  
pp. 095440892110317
Author(s):  
Katerina Mouralova ◽  
Ales Polzer ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
...  
Keyword(s):  
Surface Topography ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Wire Electrical Discharge Machining ◽  
Nickel Based Superalloy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The unconventional technology of wire electrical discharge machining is a key engineering technology, designed primarily for machining of conventionally difficult machine materials. One of them is nickel alloys, which are majorly used in the aerospace and energy industries. The subject of research in this study was specifically the B1914 nickel-based superalloy, which was subjected to many analyses leading to an overall optimization of its machining using wire electrical discharge machining. In order to determine the effect of machine parameters setup (pulse off time, gap voltage, discharge current, pulse on time and wire feed) on cutting speed, topography, morphology, surface and subsurface layer quality, an extensive Box–Behnken design experiment consisting of 46 rounds was carried out. The analyses of the condition of the surface and subsurface layers were performed, including their chemical composition and changes caused by wire electrical discharge machining. It was found out that the factors like pulse off time, discharge current and pulse on time have the greatest effect on the cutting speed, although from the point of view of surface topography the parameter pulse off time is not significant. The remaining two parameters cause the cutting speed to act against the surface topography i.e. with the increasing cutting speed, the surface topography gets worse and vice versa.

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