scholarly journals Assessment on the Optimum Performance of a Novel 3 Axes Micro EDM Developed for Commercial Applications

2021 ◽  
Vol 71 (2) ◽  
pp. 305-316
Author(s):  
P Suresh ◽  
Raja K Venkatesh
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Low Cost ◽  
Circulation System ◽  
Stainless Steel 316L ◽  
Automatic Driving ◽  
Spark Gap ◽  
Commercial Applications ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract A low cost three axes commercial microEDM machine has been developed indigenously in order to implement precision micromachining. The developed microEDM consists of various components such as machining chamber, X-Y table, tool feed and tool holder assembly, dielectric circulation system, power supply and automatic driving devices to control the spark gap distance. The setup is capable of performing the 8µm movement in Z-axis.The developed 3 axes machine and the commercial available machine are investigated with the most important process parameters such as Current, Pulse on time and Pulse off time in order to study the Material Removal Rate (MRR) and Tool Wear Rate (TWR). The material chosen for the current research is Stainless Steel 316L, which has high corrosion resistance and the electrode was tungsten 300µm. In most of the experiments, the developed machine has performed with 6.52% higher MRR and 26.10% Lower TWR. This is due to the effective spark gap circuit developed with the use of hall current sensor.The mathematical model of MRR and TWR are obtained by correlating the process parameter using Response Surface Methodology (RSM).The chosen objectives are contradictory in nature, we employ a non-dominated Genetic algorithm to find the optimal process parameters. The developed 3 axes microEDM has yield a 10.14% and 33.12% better performance on optimum maximum MRR and minimum TWR respectively when compared to the commercial machine.

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

scholarly journals Multi-Objective Optimization of Process Parameters for Powder Mixed Electrical Discharge Machining of Inconel X-750 Alloy Using Taguchi-Topsis Approach

2021 ◽  
Vol 71 (1) ◽  
pp. 1-18
Author(s):  
Basha Shaik Khadar ◽  
Raju M. V. Jagannadha ◽  
Kolli Murahari
Keyword(s):  
Boron Carbide ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Technique ◽  
Dielectric Fluid ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

Abstract The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

Effect of WEDM process parameters on machinability of Nimonic75 alloy using brass wire

2020 ◽  
Vol 17 (3) ◽  
pp. 389-397
Author(s):  
Harvinder Singh ◽  
Vinod Kumar ◽  
Jatinder Kapoor
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Content Type ◽  
Response Characteristics ◽  
Nickel Based Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Purpose This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly used in the aerospace industry for its strength at high temperature. Design/methodology/approach One factor at a time (OFAT) approach has been used to perform the experiments. Pulse on time, pulse off time, peak current and servo voltage were chosen as input process parameters. Cutting speed, material removal rate and surface roughness (Ra) were selected as output performance characteristics. Findings Through experimental work, the effect of process parameters on the response characteristics has been found. Results identified the most important parameters to maximize the cutting speed and material removal rate and minimize Ra. Originality/value Very limited research work has been done on WEDM of Nickel-based alloy Nimonic75. Therefore, the aim of this paper to conduct preliminary experimentation for identifying the parameters, which influence the response characteristics such as material removal rate, cutting speed, Ra, etc. during WEDM of Nickel-based alloy (Nimonic75) using OFAT approach and found the machinability of Nimonic75 for further exhaustive experimentation work.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

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.

Sensitivity analysis and optimization of EDM process parameters

2019 ◽  
Vol 43 (1) ◽  
pp. 13-25 ◽  
Author(s):  
Uvaraja Ragavendran ◽  
Ranjan Kumar Ghadai ◽  
Akash Kumar Bhoi ◽  
Manickam Ramachandran ◽  
Kanak Kalita
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Significance ◽  
Empirical Models ◽  
Optimization Techniques ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) is a broadly used nonconventional material removal process for the machining of conductive work material irrespective of their hardness. In this article, empirical models for material removal rate (MRR) and surface roughness (Ra) of the workpiece are developed based on the extensive experiments performed on a special steel (WP7V) workpiece using a copper electrode. To account for the various parameters, an experimental design based on response surface methodology (RSM) is conducted considering three different factors namely — current, pulse-on-time, and pulse-off-time, each having three different levels. Analysis of variance (ANOVA) is conducted to test the statistical significance of the proposed empirical models. It is essential to determine the relationship and significance of input–output variation. Thus a sensitivity analysis is conducted. The interaction effect of input variables is also studied. Two different state-of-art optimization techniques, namely genetic algorithm (GA) and particle swarm optimization (PSO), are applied to predict the optimal combination of process parameters. Finally, multi-objective optimization is also carried out to simultaneously maximize MRR while minimizing Ra.

scholarly journals Parametric optimization of Edm on Hastelloy C-276 Using Taguchi L18 Technique

2018 ◽  
Vol 7 (2.7) ◽  
pp. 714 ◽  
Author(s):  
SK Khadar Basha ◽  
Murahari Kolli ◽  
M V.Jagannadha Raju
Keyword(s):  
Process Parameters ◽  
Discharge Current ◽  
Removal Rate ◽  
Extreme Environments ◽  
Industrial Applications ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Current Electrode ◽  
Pulse On Time ◽  
Pulse Off Time

Due to development in machining science the use of composites and alloys is a great deal for every industry. Hastelloy C276 the most versatile corrosion resistant nickel based super alloy which is used for industrial applications is considered for doing the            experiments .The high nickel and molybdenum content provides better corrosion resistance at extreme environments. In this report, the experiments are performed by using Taguchi L18 technique and their results are used for performance of each process parameters on their output responses. The process parameters considered for experimentation are discharge current, pulse- on- time, type of electrode and pulse off time for the output responses of material removal rate and surface roughness. Eco-friendly (drinking water) is used as a dielectric fluid. The experiments are designed and conducted using Taguchi L18 technique and analyze the influence of each process parameters on machining performance characteristics. Further, mathematical equations were developed using the statistical software MINITAB17.0.ANOVA is used for analyzing the experimental results obtained. It was observed from the response table that the average values of MRR and SR for pulse on time, discharge current, electrode are identified as important process parameters.  

Synthesis of Stir-Cast AA7050/5%B4C Composite and Optimization of EDM Response Parameters Using Taguchi Analysis

2020 ◽  
Vol 844 ◽  
pp. 104-113
Author(s):  
Arvind Kumar ◽  
Abhishek Kumar ◽  
Ram Naresh Rai
Keyword(s):  
Process Parameters ◽  
Mechanical Design ◽  
Removal Rate ◽  
Cutting Speed ◽  
Wear Property ◽  
Taguchi Analysis ◽  
Prime Concern ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Optimal Set

Machining of Automobile and aerospace components are the prime concern for close tolerance and eastern mechanical design. AA7050 is the established aluminium alloy for automobile and aerospace components. AA7050/B4C composite enhances specific strength and wear property of the alloy. The present paper aims to develop AA7050/5%B4C Composite through flux assisted Stir casting method. Characterized its microstructure for proper distribution and incorporation of the particles. Furthermore, non-conventional machining done on the composite through CNC die-sinking EDM with process parameters Peak current (Ip), Pulse on time (Ton), and Pulse off time (Toff). The experiments are designed by Taguchi L9 orthogonal array to obtain the machining responses like Material removal rate (MRR), Surface roughness, (SR) and cutting speed (Cs). Further the responses are optimised using Taguchi analysis considering higher the better criterion for MRR and Cs and lower the better for SR. The optimal set of process parameters obtained for MRR is X3Y3Z2, for SR X3Y2Z3 and Cs X3Y3Z2. The confirmation tests conducted with optimal set of process parameters for each response. The error estimated between predicted and experimental at optimal sets is within the acceptable threshold.

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

Multi-Response Optimization of Machining Process Parameters for Wire Electrical Discharge Machining of Lead-Induced Ti-6Al-4V Alloy Using AHP–TOPSIS Method

2019 ◽  
Vol 18 (02) ◽  
pp. 213-236 ◽  
Author(s):  
A. V. S. Ram Prasad ◽  
Koona Ramji ◽  
Murahari Kolli ◽  
G. Vamsi Krishna
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Machining Process ◽  
Analytic Hierarchy ◽  
Response Characteristics ◽  
Multi Attribute Decision Making ◽  
Pulse On Time ◽  
Pulse Off Time

In this study, the effects of the process parameters on their performance characteristics of lead-induced Ti-6Al-4V alloy were investigated. Taguchi’s [Formula: see text] orthogonal array (OA) has been used to conduct the experiments. Four process parameters were considered each at three levels. Peak current, pulse-on-time, servo voltage and pulse-off-time were selected as process parameters on performance characteristics, namely, material removal rate (MRR), surface roughness (SR) and dimensional deviation (DD). A multi-attribute decision-making (MADM) technique, namely, analytic hierarchy process (AHP) and technique for order of preference by similarity to ideal solution (TOPSIS), has been used to investigate the multiple response characteristics. The weights for performance characteristics are determined by AHP. Finally, analysis of variance method has been employed effectively to bring out the influence of the process parameters associated with each performance characteristic, namely, maximization of MRR and minimization of SR and DD.

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