scholarly journals Optimization Multi Response on Electrical Discharge Machining Sinking Process Using Taguchi-Grey-Fuzzy Methods

2020 ◽  
Vol 4 (2) ◽  
pp. 209-214
Author(s):  
Rahayu Mekar Bisono ◽  
Rifky Maulana Yusron
Keyword(s):  
Tool Wear ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Duty Factor ◽  
Work Piece ◽  
Electrode Polarization ◽  
Fuzzy Methods ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Research Show

Electronic Discharge Machining (EDM) sinking applied widely in advance material manufacturing, every process parameter will count on this company. Their performance evaluated by some parameters such as surface roughness and tool wear ratio. Then they will be a dependent variable on this research. Independent variables on this research are electrode polarization, gap voltage, duty factor and pulse current.  Every variable has three levels, except electrode polarization has two levels. This research conducting using Taguchi matrix orthogonal L18 (21×33) methods. The aim of this experiment is to evaluate optimization parameter process on EDM sinking, using Taguchi-Grey-Fuzzy methods. Characteristics response optimal applied are ‘smaller better’ for surface response roughness and tool wear ratio. This research using DAC tool steel as work-piece. DAC is most widely used as die for aluminum and zinc die-casting. The aim of this research is finding contribution of variable in EDM sinking parameter. Result of this research show contribution from variable process to reduce variance total observed response simultaneously, in order are electrode polarization on 49,53%, gap voltage on 23,52%, duty factor on 5,45% and pulse current on 9,92%. From validated optimization in confirmation experiment, to conclude combination variable process optimal response value is electrode polarization on positive, gap voltage at 50V, duty factor at 0.5 and pulse current at 12A.   

scholarly journals An Influence of Parameters of Micro-electrical Discharge Machining on Wear of Tool Electrode

2017 ◽  
Vol 64 (2) ◽  
pp. 149-163 ◽  
Author(s):  
Govindan Puthumana
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Electrode ◽  
Micro Edm ◽  
Modeling And Analysis ◽  
Micro Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Main Effect

AbstractTo achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a regression relationship between tool wear ratio and the process inputs has been developed.

The Analysis of Processing Factors for Electro-Arc Machining

2013 ◽  
Vol 470 ◽  
pp. 585-588 ◽  
Author(s):  
Min Zhang ◽  
Qin He Zhang ◽  
De Zheng Kong ◽  
Yang Ren
Keyword(s):  
Tool Wear ◽  
Pulse Duration ◽  
Rotational Speed ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Material ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Input Parameters ◽  
Processing Factors

Electro-arc machining is similar with traditional electrical discharge machining (EDM) while the pulse duration of electro-arc machining is longer than that of EDM. The longer discharge was named arcing, and the arcing could lead to high material remove rate (MRR) and low tool wear ratio (TWR). Processing factors including discharge medium, tool polarity, tool material, voltage and rotational speed were chosen as input parameters on MRR and TWR. Taguchis method was used to evaluate their effects. All of the five processing factors had effects on MRR and TWR. The effects and the mechanism are also discussed.

Ringing Effect and Reversed Current Analysis of RC-Pulse Generator in Electrical Discharge Machining

2013 ◽  
Vol 770 ◽  
pp. 183-188 ◽  
Author(s):  
Min Zhang ◽  
Qin He Zhang ◽  
De Zheng Kong ◽  
Xue Bai
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Effect Theory ◽  
Low Efficiency ◽  
Ringing Effect ◽  
Reversed Current

RC-pulse generator has a simple structure and it is easy to be made and repaired. Especially RC-pulse generator can provide high frequency and low energy discharges. Therefore RC-pulse generators are used in micro-EDM field. But its high tool wear ratio and low efficiency restrict its applications. Ringing effect is considered to have effect on the defects. This research was done to study the ringing effect in electrical discharge. Taguchi method was used and discharge curves of voltage and current were recorded and analyzed. Ringing effect plays a key role in discharges and reversed current. A waveform model established with ringing effect theory is almost the same as the waveforms recorded in the experiment. Reversed current exists in almost a half time of discharge period which is the representation of ringing effect. Suitable process parameters can reduce reversed current and proper improvements could eliminate reversed current which will reduce the tool wear ratio and increase the efficiency in RC-pulse generator.

Performance and Microstructure of TiN/Cu EDM Electrodes

2012 ◽  
Vol 268-270 ◽  
pp. 82-86
Author(s):  
Jing Jing Zhang ◽  
Kai Yong Jiang ◽  
Jie Yan ◽  
Fei Wang ◽  
Xiao Wei Wang
Keyword(s):  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Ceramic Materials ◽  
Copper Electrode ◽  
Wear Ratio ◽  
Tool Wear Ratio ◽  
Edm Electrodes ◽  
Commercial Copper ◽  
Different Content

This paper is to explore the feasibility of TiN/Cu-based composite materials as electrical discharge machining (EDM) electrodes.The tool wear ratio (TWR) of EDM electrode directly reflects the machining precision. To reduce the tool wear ratio(TWR) of Cu electrode in the EDM processing, Inorganic mixture of different content of ceramic materials TiN powder and Cu powder are prepared , then pressed and sintered into EDM electrodes.Experimental results show that: in the six batchs of experiments, the tool wear ratio (TWR) of 35%TiN/Cu electrode is the least, which is about 4.98%, much less than that of commercial copper electrode . The microstructures of the TiN/Cu electrodes after electrical discharge machining (EDM) as well are analyzed in this paper.

Magnetic Field Assisted Electric Discharge Machining of Cryo-Treated Monel 400 Alloy

2015 ◽  
Vol 787 ◽  
pp. 371-375
Author(s):  
Rahul R. Jadhav ◽  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Magnetic Field ◽  
External Magnetic Field ◽  
Tool Wear ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Engineering Properties ◽  
Work Piece ◽  
Unconventional Machining ◽  
Edm Process

Monel alloys are pioneering materials which have exceptional engineering properties such as corrosion resistance, high toughness and show good response to cryogenic treatment. It finds uses in ship building, nuclear aerospace, missile and valve industries. These materials shows strain hardening effect which results in tool wear and in some cases tool breakage when machined by conventional methodshence, unconventional machining such as electrical discharge machining (EDM)discoverspurpose for machining of such materials. Researchers have recognized relation between electrical input process parameters of EDM process and output parameters of EDM process. But researchers have not investigated the influence of external magnetic field and cryo-treatment of work piece on EDM performance measures namely material removal rate (MRR) and tool wear rate (TWR). In vision of this the objective of present work was to study the effect of gap current, external magnetic field and cryogenic treatment of work part on MRR and TWR. Experiments were carried out by creating a 3 mm square hole on Monel400 alloys. Based on experimental results it was found that as gap current increases the MRR and TWR increases for untreated work part. For treated work part MRR increases and TWR decreases with increasein gap current. MRR and TWR increases with constant gap current for untreated work part, as magnetic field increases. For treated work part MRR increases and TWR decreases with increase in magnetic field at constant gap current.

Analysis of MRR and TWR on OHNS Die Steel with Different Electrodes Using Electrical Discharge Machining

2016 ◽  
Vol 22 ◽  
pp. 112-120 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Tool Wear Rate

Electrical Discharge Machining is a machining method primarily used for hard metals or those that are impossible to be machined with traditional techniques. The experimental investigation of material removal rate and tool wear rate during machining of oil hardened non-shrinking steel with brass and copper electrodes using EDM machine was carried out in this paper. This investigation presents the analysis and evaluation of heat affected zones and surface finish of the work piece using different tool electrodes and varying the machine parameters. The commercial grade kerosene oil has been used as dielectric fluid. The effect of various important EDM parameters such as discharge current (Ip) 2 to12A, pulse duration (Ton and Toff) and sparking voltage (V) of 80±5% have been used to yield the response in terms of Material Removal Rate (MRR) and Tool Wear Rate (TWR). Further a detailed analysis of the heat affected regions was also been carried out by using scanning electron microscopy.

Study the Effects of Dielectric Type on the Machining Characteristics of γ-Ti Al in Electrical Discharge Machining

2017 ◽  
Vol 33 ◽  
pp. 40-49
Author(s):  
Mohammad Reza Shabgard ◽  
Hossein Faraji ◽  
Behnam Khosrozade ◽  
Hadi Eivazi-Bagheri ◽  
Keivan Amini
Keyword(s):  
Intermetallic Compound ◽  
Tool Wear ◽  
Electric Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Deionized Water ◽  
Surface Cracks ◽  
Electric Discharge Machining ◽  
Tool Wear Ratio

The current study surveys the results of using deionized water and kerosene as dielectrics in the machining outputs of γ-TiAl intermetallic compound obtained in electric discharge machining. Influences of these different dielectrics properties on machining speed, tool wear, surface cracks and roughness were compared. Scanning electron microscopy micrographs were prepared to investigate influences of dielectrics on the surface characteristics of electrically discharged samples. Results indicate which by kerosene dielectric; the material removal rate (MRR) is further compared to another one. But deionized water as dielectric causes higher tool wear ratio than kerosene dielectric. Electrical discharged samples in deionized water have higher surface roughness, in addition it contains surface cracks, whereas kerosene dielectric results better surface finish in low pulse current. According to XRD spectra electric discharge machining in deionized water and kerosene dielectrics produces Ti3 Al intermetallic compound on the produced surface.

Electrical Discharge Machining (EDM): Selection of Dielectric in Machining ASSAB 718HH

2012 ◽  
Vol 622-623 ◽  
pp. 520-524
Author(s):  
Norliana Mohd Abbas ◽  
Darius Gnanaraj Solomon
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Plasma Channel ◽  
Removal Rate ◽  
Dielectric Strength ◽  
Work Piece ◽  
Electrical Discharges ◽  
Tool Wear Ratio ◽  
Selection Of

Electrical Discharge Machining (EDM) in Malaysia is widely used in mould making industries. Parts for automotive, defence and telecommunication industries are also other examples of the products produced. The process is based on removing material from a part by a series of repeated electrical discharges between a tool called electrode and the work piece with the presence of dielectric. The dielectric serves as transportation of removed particles, remains electrically non-conducting until the breakdown voltage is reached, reconditions the dielectric strength, increases the energy density in plasma channel and cools the electrode. This paper presents the machining of ASSAB 718HH work pieces with copper tool using EDM die sinking method. Three commercial EDM dielectrics; Kerosene, Novis and Amoil were tested and comparison between material removal rate (MRR), tool wear ratio (TWR) and surface finish (SF) are given. Through Pugh Method, result shows that ASSAB 718HH is best machined with Novis.

scholarly journals The Methodologies Adopted To Improve the Machinability in Die-Sinking EDM

2019 ◽  
Vol 9 (1S4) ◽  
pp. 645-647
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Surface ◽  
High Hardness ◽  
Machining Process ◽  
Work Piece ◽  
Machining Processes

Electrical discharge machining (EDM) is one of the oldest nontraditional machining processes, commonly used in automotive, aerospace and ship building industries for machining metals that have high hardness, strength and to make complicated shapes that cannot be produced by traditional machining techniques. The process is based on the thermoelectric energy between the work piece and an electrode. EDM is slow compared to conventional machining, low material removal rate, high surface roughness, high tool wear and formation of recast layer are the main disadvantages of the process. Tool wear rate, material removal rate and surface quality are important performance measures in electric discharge machining process. Numbers of ways are explored by researchers for improving and optimizing the output responses of EDM process. The paper summarizes the research on die-sinking EDM relating to the improvements in the output response.

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