scholarly journals An investigation of wire offset and surface morphology of Die Steel D-3 on Wire EDM by using RSM-CCD

2021 ◽  
Vol 27 (2) ◽  
pp. 112-118
Author(s):  
Mohd Faizan Hasan ◽  
Prem Kumar Bharti ◽  
Mohd Reyaz Ur Rahim
Keyword(s):  
Surface Morphology ◽  
Thermal Stresses ◽  
Wire Edm ◽  
Input Process ◽  
Sem Images ◽  
Peak Current ◽  
Wire Tension ◽  
Die Steel ◽  
Pulse On Time ◽  
Central Composite

Abstract The work investigated the effect on wire offset and surface morphology, with input process parameters as peak current, pulse on time, wire tension over Die Steel D3. Some of experiments were performed by using response surface methodology (RSM) as the design of experiment with central composite design (CCD) technique for the analysis. The ANOVA results annotate that the model is significant. Wire Tension and peak current are observed to have major impact on wire offset during machining operation and surface morphology. The scanning electron microscope (SEM) images confirmed that the thermal stresses produced during the machining of the workpiece resulted in the development of microcracks, craters and spherical module. Due to higher thermal gradient i.e., higher peak current and pulse on-time larger cracks and melted deposits were observed.

scholarly journals Modeling of Residual Stress and Surface Damage of AISI 4340 using Copper-Tungsten Tool in Die Sinking EDM

2019 ◽  
Vol 9 (1) ◽  
pp. 3050-3055
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Thermal Stresses ◽  
Surface Damage ◽  
Thermal Gradients ◽  
Sem Images ◽  
Micro Cracks ◽  
Pulse On Time ◽  
Central Composite ◽  
Aisi 4340

The present work concentrates on the modeling of the residual stress and cracks induced during the machining of AISI 4340 in die-sinking EDM. Response surface methodology with rotatable central composite design is used with peak current, pulse on duration, voltage and pulse duty factor as process parameters. The relation between these process parameters and induced residual stress and cracks is established. The results of ANOVA elucidates that the present model is significant. Voltage and pulse on time are observed to have major dominance on residual stress. The SEM images reviled that micro-cracks resulted from the thermal stresses developed during machining of the workpiece. At higher levels of pulse on duration, wider cracks are observed due to high thermal gradients.

Parametric investigation of tool wear rate in EDM of Fe-based shape memory alloy: microstructural analysis and optimization using genetic algorithm

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ranjit Singh ◽  
Ravi Pratap Singh ◽  
Rajeev Trehan
Keyword(s):  
Tool Wear ◽  
Tool Electrode ◽  
Tool Wear Rate ◽  
Sem Images ◽  
Peak Current ◽  
Content Type ◽  
Desirability Approach ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Purpose This study aims to experimentally investigate the influence of considered process parameters, i.e. pulse on time, pulse off time, peak current and gap voltage, on tool wear rate (TWR) in electrical discharge machining (EDM) of iron (Fe)-based shape memory alloy (SMA) through designed experiments. The parametric optimization for TWR has also been attempted using the desirability approach and genetic algorithm (GA). Design/methodology/approach The response surface methodology (RSM) in the form of Box–Behnken design has been used to scheme out the experiments. The influence of considered process inputs has also been observed through variance analysis. The reliability and fitness of the developed mathematical model have been established with test results. Microstructure analysis of machined samples has also been evaluated and analyzed using a scanning electron microscope (SEM). SEM images revealed the surface characteristics such as micro-cracks, craters and voids on the tool electrode surface. SEM images provide information about the surface integrity and type of wear on the surface of the tool electrode. Findings The input parameters, namely, pulse on time and pulse off time, are major influential factors impacting the TWR. High TWR has been reported at large pulse on time and small pulse off time conditions whereas higher TWR is reported at high peak current input settings. The maximum and minimum TWR values obtained are 0.073 g/min and 0.017 g/min, respectively. The optimization with desirability approach and GA reveals the best parametric values for TWR i.e. 0.01581 g/min and 0.00875 g/min at parametric combination as pulse on time = 60.83 µs, pulse off time = 112.16 µs, peak current = 18.64 A and gap voltage = 59.55 V, and pulse on time = 60 µs, pulse off time = 120 µs, peak current = 12 A and gap voltage = 40 V, correspondingly. Research limitations/implications Proposed work has no limitations. Originality/value SMAs have been well known for their superior and excellent properties, which make them an eligible candidate of paramount importance in real-life industrial applications such as orthopedic implants, actuators, micro tools, stents, coupling, sealing elements, aerospace components, defense instruments, manufacturing elements and bio-medical appliances. However, its effective and productive processing is still a challenge. Tool wear study while processing of SMAs in EDM process is an area which has been less investigated and of major concern for exploring the various properties of the tool and wear in it. Also, the developed mathematical model for TWR through the RSM approach will be helpful in industrial revelation.

scholarly journals Experimental investigation on electro-discharge surface modification phenomenon of P20+Ni die steel using green P/M composite electrode

2021 ◽  
Vol 15 (3) ◽  
pp. 8390-8404
Author(s):  
JAYANTIGAR L RAMDATTI ◽  
A. V. Gohil ◽  
K. G. Dave
Keyword(s):  
Surface Modification ◽  
Compaction Pressure ◽  
Spectroscopy Analysis ◽  
Die Steel ◽  
Aisi P20 ◽  
Desirability Approach ◽  
Pulse On Time ◽  
Optimal Set ◽  
Edm Process ◽  
Central Composite

In the present work, attempts have been made to optimize the EDM process with an aspect of surface modification of AISI P20+Ni die steel using powder metallurgy (P/M) electrode. Experiments have been performed according to central composite rotatable (CCD) design using response surface methodology (RSM). Effects of compaction pressure (Cp), peak current (Ip), pulse-on time (Ton), and duty cycle (τ) were correlated with surface roughness (SR) and microhardness (MH). Adequacy of mathematical model has been checked by performing ANOVA. Composite desirability approach was used to obtain optimal set of parameters for minimum SR and maximum MH. The errors between the predicted and experimental value of responses at the optimal set of parameters for SR and MH maintain within 5.26% and -3.64% respectively. Scanning electron microscope and energy dispersive spectroscopy analysis confirmed the transfer of P/M electrode material on the work surface. The result indicates three times improvement in microhardness of EDMed surface.

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

CORROSION PROTECTION OF ELECTROLESS PLATING Ni-P INCLUDING TiN NANOPARTICLES FOR BIPOLAR PLATES OF PEMFCs

2018 ◽  
Vol 25 (02) ◽  
pp. 1850052 ◽  
Author(s):  
GAO PINGPING ◽  
OUYANG CHUN ◽  
XIE ZHIYONG ◽  
TAO TAO
Keyword(s):  
Corrosion Resistance ◽  
Surface Morphology ◽  
Electroless Plating ◽  
Shell Structure ◽  
Compact Surface ◽  
Proton Exchange ◽  
Core Shell ◽  
Tin Coating ◽  
Sem Images ◽  
Core Shell Structure

The Ni-P/TiN coating was used as bipolar plate by electroless plating on Ti. Surface morphology and phase structure of the coatings were characterized by SEM and XRD, respectively. Corrosion resistance of Ni-P and Ni-P/TiN coating was measured in the simulated solution of Proton exchange membrane fuel cells (PEMFCs). The interfacial contact resistance (ICR) was conducted by applied different forces. SEM images indicated that the particles of core–shell structure were formed on the surface of coating on Ti substrate. The core–shell structure was composed of TiN core and Ni-P electroless plating shell. Compared with Ni-P coatings, the Ni-P/TiN coating showed better corrosion resistance behaviors and low ICR (below 10[Formula: see text]m[Formula: see text][Formula: see text] cm[Formula: see text] under pressure of 200 N/cm[Formula: see text]. TiN particles and distribution of core–shell were in favor of the formation of coating and compact surface morphology. The good conductivity was attributed to the compact surface morphology of coating. The Ni-P/TiN coating showed excellent interfacial conductivity and good corrosion resistance at applied high potential in simulated solution of PEMFCs.

Preparation of Electrodeposited Ni-CNTs Nanocomposite Coatings with Highly Wear and Corrosion Resistance Properties

2012 ◽  
Vol 548 ◽  
pp. 101-104 ◽  
Author(s):  
W. Shao ◽  
D. Nabb ◽  
N. Renevier ◽  
I. Sherrington ◽  
J.K. Luo
Keyword(s):  
Mechanical Property ◽  
Carbon Nanotubes ◽  
Corrosion Resistance ◽  
Surface Morphology ◽  
Corrosion Property ◽  
Nanocomposite Coatings ◽  
Sem Images ◽  
Wear And Corrosion ◽  
Watts Bath ◽  
Wear And Corrosion Resistance

Ni-carbon nanotubes nanocomposite coatings were obtained from a Watts bath containing uniformly dispersed carbon nanotubes (CNTs). The surface morphology was investigated by the SEM images of coatings. The mechanical property and corrosion resistance of the nanocomposite coatings were investigated. This study revealed these CNTs reinforced Ni nanocoatings have improved mechanical and corrosion property.

Multi-Response Optimization of Wire-EDM Process Parameters of Titanium Alloy Using Taguchi Method and Grey Relational Analysis

2015 ◽  
Vol 772 ◽  
pp. 245-249
Author(s):  
A. Ramamurthy ◽  
R. Sivaramakrishnan ◽  
S. Venugopal ◽  
T. Muthuramalingam
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Wire Edm ◽  
Relational Analysis ◽  
Response Optimization ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

It is very important and complexity to find the optimum values of wire EDM process parameters and contribution of each parameter to attain the better performance characteristics. In this study, an attempt has been made to optimize those parameters while machining the titanium alloy. Since the process involves more one than one response parameter, it is essential to carry out the multi-response optimization methodology .The experiments have been conducted with different levels of input factors such as pulse on time,pulse off time and wire tension based on Taguchi L9 orthogonal table.Wire EDM optimal process parameter has been identified using grey relational analysis and significant parameter has been determined by analysis of variance. Experimental results have indicated that the multi-response characteristic such as material removal rate and surface roughness can be improved effectively through grey relational analysis.

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

scholarly journals Optimisation of Biogas Production through Variation of PH, Detention Time and Ratio of Substrate to Water for Rural Utilization

2019 ◽  
Vol 2 (1) ◽  
pp. 52-59 ◽  
Author(s):  
A G Jiya ◽  
U J Ijah ◽  
M Galadima ◽  
U G Akpan
Keyword(s):  
Rural Community ◽  
Numerical Optimization ◽  
Biogas Production ◽  
High Yield ◽  
Input Process ◽  
Domestic Waste ◽  
Detention Time ◽  
Biogas Yield ◽  
Optimal Values ◽  
Central Composite

A response surface methodology (RSM) was utilized in this study for optimisation of biogas production process. The optimal values of process parameter capable of giving a high yield of biogas were established. A biodigester of 20 liters capacity capable of producing biogas from rural household domestic waste was designed, constructed and used in the study. Its major units are the anaerobic and gas collecting units. The process parameters investigated are the pH of the substrate, detention time and ratio of substrate to water while the yield of biogas was used as performance characteristics. The experiment was based on a central composite rotatable design (CCRD). The results revealed that the highest yield of biogas was obtained from a combination of detention time of 30 days, ratio of substrate to water of 1:1 and pH of 7, while the least yield of biogas of 11 cm3 was obtained from combination of detention time of 30 days, ratio of substrate to water of 1:3 and pH of 2. Numerical optimization carried out with the goal of maximizing the biogas yield revealed optimum values of detention time of 40 days, the ratio of substrate and water used; 1:2 and pH of 6.71 for biogas of 771.77 cm3 with the desirability of 0.9850. The detention time had the highest significant effects on the yield of biogas. The results of this study provided standard input process variables capable of yielding the optimum yield of biogas for the rural community.

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