scholarly journals EDM PROCESS PARAMETER OPTIMIZATION FOR EFFICIENT MACHINING OF INCONEL-718

2020 ◽  
Vol 18 (3) ◽  
pp. 473
Author(s):  
Ankit Singh ◽  
Ranjan Kumar Ghadai ◽  
Kanak Kalita ◽  
Prasenjit Chatterjee ◽  
Dragan Pamučar
Keyword(s):  
Wear Rate ◽  
Inconel 718 ◽  
Removal Rate ◽  
Subjective Evaluation ◽  
Fluid Pressure ◽  
Objective Evaluation ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Machining Performance ◽  
Edm Process

In the present work, multi-response optimization of electro-discharge machining (EDM) process is carried out based on an experimental analysis of machining superalloy Inconel-718. The study aims at optimizing and determining an optimal set of process variables, namely discharge current (), pulse-on duration () and dielectric fluid-pressure () for achieving optimal machining performance in EDM. Nine independent experiments based on L9 orthogonal array are carried out by using tungsten as the electrode. The productivity performance of the EDM process is measured in terms of material removal rate (MRR) and its cost parameter is measured in terms of tool wear rate (TWR) and electrode wear rate (EWR). The TOPSIS is used in conjunction with five different criterion weight allocation strategies— (namely, mean weight (MW), standard deviation (SDV), entropy, analytic hierarchy process (AHP) and Fuzzy). While MW, SDV and entropy are based on the objective evaluation of the decision-maker (DM), the AHP can model the DM’s subjective evaluation. On the other hand, the uncertainty in the DM’s evaluation is analyzed by using the fuzzy weighing approach.

SKD 61 Material Surface Treatment with Electric Discharge Machining Using Cu, CuCr & Graphite Electrodes and Dielectric Fluid Jatrophacurcas

2013 ◽  
Vol 789 ◽  
pp. 307-312
Author(s):  
Triyono ◽  
Dedi Priadi ◽  
Eddy S. Siradj ◽  
Winarto
Keyword(s):  
Surface Treatment ◽  
Electric Discharge ◽  
Removal Rate ◽  
White Layer ◽  
Material Surface ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Graphite Electrodes ◽  
Edm Process

The emergence of white layer in each process of Electric Discharge Machining (EDM) becomes the focus of attention of the experts. It is harder than the base metal would be advantageous to withstand friction engine components, such as the plastic molding industry. From various studies it has been reported that the increase in the value of hardness of white layer either due to migration of the electrode material and dielectric fluid to the white layer. This paper discusses the influence of electrodes Cu, CuCr and graphite as well as jatrophacurcas dielectric fluid to the surface of the material SKD 61, microhardness of the white layer, Tool Wear Rate (TWR) of Material Removal Rate (MRR), Surface roughness (Ra) and the microstructure. Initial studies conducted are the transesterification and characterization of jatrophacurcas to determine the dielectric strength and the content of metal elements. Furthermore, the EDM testing is done to dies steel of SKD 61 using the electrodes of Cu, CuCr and Graphite. The use of jatrophacurcas yield the best MRR when using Graphite electrodes followed Cu last CuCr. While the smallest TWR produced by Cu electrode, CuCr and then the highest is Graphite. The relative wear which is the ratio TWR with MRR, for the three types of electrodes is always great at a small current then decreases and then tends to be stable with the increase of electric current. Jatrophacurcas for the three types of electrodes provide higher TWR than kerosene. This means that migration of materials is beneficial because larger material, but in terms of the geometric accuracy of the product can lead to decreasing of dimensional tolerances. Vickers hardness values of white layer is achieved by CuCr electrodes, Graphite lowest. Microstructural observation results of EDM white layer using graphite electrodes produce a more uniform thickness than the white layer using Cu and CuCr electrodes. The conclusion of this study that jatrophacurcas can be used as a dielectric fluid in EDM process, because electrode wear during EDM process is relatively high compared with kerosene that is mean more profitable in the surface treatment process of dies steel of SKD 61.

The Effects of Dielectric Fluid Viscousity on Chips Formation Rate and Electrode Wear Rate in Electrical Discharge Machining of SKD 61 Steel

2018 ◽  
Vol 929 ◽  
pp. 177-185 ◽  
Author(s):  
Triyono ◽  
Joko Riyono ◽  
Nur Fadli ◽  
Daisman Purnomo Bayyu Aji
Keyword(s):  
Wear Rate ◽  
Jatropha Curcas ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Formation Rate ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Fluid Mixture ◽  
Edm Process

Electrical Discharge Machining (EDM) is a machine for cutting workpieces with thermal energy derived from electrical spark from tool (cathode) to workpiece (anode). As EDM process requires a dielectric fluid in the cutting operation, the characteristics of the dielectric fluid play an essential role for obtaining excellent cutting. Jatropha curcas has been demonstrated for use as a dielectric fluid in EDM process. However, the drawback is that the Rate of Metal Removal (RMR) is lower than that of generally-used dielectric fluid in industry. We consider that the cause is a much higher viscousity of the jatropha curcas. This study was conducted to investigate the characteristics of a new dielectric fluid mixture of jatropha curcas and kerosene. Kerosene was used in the mixture to reduce the viscousity of the jatropha curcas since the kerosene has a much lower viscousity. The measurement of the viscousity of the fluid mixture was performed using an Ostwald viscousimeter. Evidently, when the jatropha curcas mixed with the kerosine the viscousity of the mixture is lower than that of the pure jatropha curcas. The effects of the viscousity of the fluid mixture were investigated by measuring the RMR and Tool Wear Rate (TWR). The RMR and TWR were determined by calculating the difference in the weight of the workpiece and the tool, respectively, before and after the cutting for a certain cutting interval. The measurements were carried out for eleven different concentration of the fluid mixture by varying the current of 15 and 21 Amp, with replication of 3 times. As the result, the energy released during the cutting process affects the values of TWR and RMR. It was also found that in contrast to the effect on TWR, the RMR was not influenced by the viscousity of the mixture.

Effects of Pulse Duration and Current on EDM Process of Allegheny Ludlum D2 Tool Steel

2013 ◽  
Vol 315 ◽  
pp. 369-373
Author(s):  
S. Sulaiman ◽  
A.A. Khan ◽  
M.A. Razak ◽  
M.R. Ibrahim ◽  
M.S. Yusof
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Pulse Duration ◽  
Tool Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Edm Process

The purpose of this paper is to study the effect of current on performance of EDM process of Allegheny Ludlum D2 Tool Steel (UNS T30402). The effect of varying the machining parameters on the machining responses such as material removal rate (MRR), electrode wear rate (EWR), and surface roughness (Ra) have been investigated. In this study, circular shape of copper was used as an electrode with surface area of 100mm². The experiments were repeated for three different values of pulse duration (100µs, 200µs and 400µs) with combination of three different values of discharge current (12A, 16A and 24A). It was found that the pulse duration and current give significant effect on MRR, EWR and Ra. An increase in the pulse durations causes an increase in the MRR and Ra, but a decrease in the EWR. Meanwhile, the effect of currents on EDM performance shows that the increasing currents led to an increase in the MRR, EWR and Ra.

PENGARUH VARIABEL PEMOTONGAN TERHADAP KEAUSAN ELEKTRODA DAN BENDA KERJA PADA PROSES EDM

ROTASI ◽  
2014 ◽  
Vol 16 (4) ◽  
pp. 9
Author(s):  
Petrus Londa
Keyword(s):  
Wear Rate ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Signal To Noise Ratio ◽  
Electrode Wear ◽  
Signal To Noise ◽  
Electrode Wear Rate

Keausan elektroda pada proses EDM die sinking adalah peristiwa yang tidak dapat di hindari, namun dengan mengatur variabel pemotongan yang sesuai, diharapkan keausan yang terjadi se-minim mungkin sehingga dapat menjamin tingkat akurasi ukuran pada benda kerja yang di hasilkan. Pada penelitian ini di pilih metode Taguchi untuk menentukan variabel pemotongan yang optimum pada elektroda tembaga dan benda kerja dari bahan K460 (amutit S). Taguchi L9 orthogonal array, signal-to-noise ratio (S/N ratio) dan analysis of variance (ANOVA) dapat menentukan performa variabel proses EDM (PON, POFF, QDON dan GAP) dengan parameter yang di teliti adalah Electrode Wear Rate (EWR) dan Material Removal Rate (MRR). Hasil dari eksperimen tersebut di tampilkan dalam bentuk tabel-tabel dan grafik

Study on the Wear in the EDM Based on the Field Emission Theory

2014 ◽  
Vol 543-547 ◽  
pp. 3750-3753
Author(s):  
Shu Yang Liu ◽  
Zhi Hong Han
Keyword(s):  
Wear Rate ◽  
Theoretical Prediction ◽  
Field Emission ◽  
Wear Mechanism ◽  
Electrode Materials ◽  
Positive Electrode ◽  
Electrode Wear ◽  
Prediction Equations ◽  
Sputtering Power ◽  
Edm Process

Based on the analysis of the sputtering power of field-emission electrons which hit on the end surface of positive electrode, the wear mechanism of electrode materials was studied during positive EDM process The theoretical prediction equations of maximum and minimum electrode wear rate were deduced respectively in this paper.

Investigating the Effect of Machining Parameters on Microdrilling of Titanium Grade 19 Alloy

2013 ◽  
Author(s):  
Shivraj Yeole ◽  
Nagabhushana Ramesh Nunna ◽  
Balu Naik Banoth
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Micro Edm ◽  
Electrode Diameter ◽  
Micro Holes ◽  
Titanium Grade ◽  
Edm Process

Electrical Discharge Micro Drilling (EDMD) is considered as one of the most effective method for machining difficult to cut and hard materials like titanium alloy. However, selection of process parameters for achieving superior surface finish, higher machining rate and accuracy is a challenging task in drilling micro-holes. In this paper, an attempt is made to optimize micro-EDM process parameters for drilling micro holes on titanium grade 19 alloy. In order to verify the optimal micro-EDM process parameters settings, material removal rate (MRR), electrode wear rate (EWR) and over cut (OC) were chosen as the responses to be observed. Pulse on time, pulse off time, electrode diameter and current were selected as the governing process parameters for evaluation by Taguchi method. Nine micro holes of 300 μm, 400 μm and 500 μm were drilled using L9 orthogonal array (OA) design. Optimal combination of machining parameters were obtained through Signal-to-Noise (S/N) ratio analysis. It is seen that machining performances like material removal rate and overcut are affected by the peak current whereas electrode wear is affected by peak current and electrode diameter. Morphology of the micro holes has been studied through SEM micrographs of machined micro-hole.

Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM

2013 ◽  
Vol 675 ◽  
pp. 365-369 ◽  
Author(s):  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Hai Ping Tsui ◽  
Yuan Feng Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Dielectric Fluids ◽  
Edm Process

The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

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.

Effect of Higher Peak Current and Pulse Duration on EWR of Copper Electrode when Electrical Discharge Machining (EDM) of Inconel 718

2013 ◽  
Vol 845 ◽  
pp. 945-949
Author(s):  
S. Ahmad ◽  
Mohd Amri Lajis
Keyword(s):  
Wear Rate ◽  
Pulse Duration ◽  
Electrode Surface ◽  
Inconel 718 ◽  
Copper Electrode ◽  
Work Piece ◽  
Electrode Wear ◽  
Peak Current ◽  
Electrode Wear Rate ◽  
Pulse On Time

In this work, the electrode wear rate (EWR) and electrode surface characteristic of copper electrode when EDM of Nickel Based Super Alloy, Inconel 718 at higher peak current and pulse duration were analyzed. Experiments were conducted using Inconel 718 as a work piece and copper as an electrode with a kerosene dielectric under different peak currents and pulse durations. Peak current, Ip within a range of 20A to 40A and pulse duration (or pulse on-time), ton within a range of 200μs to 400μs are selected as the main parameters. In this study, EWR were measured using digital weight balance (accuracy 0.01mg) and by using Scanning Electron Microscope (SEM), the surface texture of the electrode in order to evaluate the material deposited on the electrode surface. The results have shown that machining at a lowest peak current of 20A and highest pulse duration of 400μs yields the lowest electrode wear rate (EWR) of -0.01mm3/min. The pulse duration is significantly affecting the EWR. It also revealed that, the deposited of carbon and work piece material is occurred on the electrode surface for all machining conditions.

Electrical Discharge Machining of SiC and Gr Reinforced 6061-T6 Aluminum Alloy Hybrid Composite Fabricated by Friction Stir Processing

2013 ◽  
Author(s):  
Murahari Kolli ◽  
Devaraj Aruri ◽  
Kumar Adepu
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Machining Parameters ◽  
Machining Performance ◽  
Friction Stir

Aluminum based hybrid composites are advanced materials having the properties of high hardness, superior wear resistance, strength, high elevated temperature and low thermal expansion coefficient. These hybrid composites are widely used in industries like automobile and aerospace. In this present paper 6061-T6 Aluminum alloy reinforced with SiC and Gr particles, hybrid composites are fabricated by using Friction stir processing (FSP) technique. It prevents the further development of hybrid composites for machining by nonconventional methods like water jet and laser cutting process. Electrical discharge machining (EDM) is used for machining the complex shapes of the material. This paper presents an overview of EDM studies conducted on the Al-SiC/Gr hybrid composites using a copper electrode in EDM. The EDM experiment machining parameters such as the dielectric fluid, peak current, pulse on, pulse off times are changed to explore their effects on machining performance, material removal rate (MRR), Tool wear rate (TWR), and surface roughness (SR). It is observed that the MRR and SR of the Al-SiC/Gr hybrid composites increase with an increase in the current.

Sign in / Sign up

Export Citation Format

Share Document