Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (2A) ◽  
pp. 226-231
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected on HAZ with 67.219% contribution.

scholarly journals Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (3A) ◽  
pp. 319-324
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that the model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected by HAZ with 67.219% contribution.

Influence of Process Parameters on Material Removal Rate in Electrical Discharge Machining Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 91-95
Author(s):  
Tran Thi Hong ◽  
Nguyen Hong Linh ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Vu Thi Lien ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Work Piece ◽  
Influence Of Process Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

This paper aims to find the impact of Electric Discharge Machining (EDM) factors on material removal rate (MRR) for 90CrSi alloy steel. Five three-level factors including pulse on time (Ton), pulse off time (Toff), pulse current (IP), server voltage (SV), and diameter of work-piece (dw) are investigated to explore their contribution on MRR by using Taguchi method in twenty-seven experiments based on an orthogonal array L27 (35). The findings realize that MRR is the most affected by the pulse current while the effect of the dw is the smallest. Based on ANOVA analysis, an optimal model of MRR has been developed and verified by comparing with the experiment result. The applicability of this proposed method can be used for further studies in EDM process.

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).

scholarly journals Empirical Modeling of Average Cutting Speed during WEDM of Hastelloy C22

2018 ◽  
Vol 249 ◽  
pp. 02003 ◽  
Author(s):  
Bhupinder Singh ◽  
Joy Prakash Misra
Keyword(s):  
Process Parameters ◽  
Cutting Speed ◽  
Performance Measure ◽  
Empirical Modeling ◽  
Workpiece Material ◽  
Peak Current ◽  
The Right ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

Cutting speed (CS) is a key performance measure to achieve optimal utilization of the WEDM process. However, input process parameters of WEDM and combination of wire and workpiece material greatly hamper CS and hence productivity and machining efficiency. Therefore, it is essential to pick the right combination of parameters and wire and workpiece material to obtain better CS. In this paper, four process parameters: Pulse-on time, Pulse-off time, Spark-gap voltage, and Peak current were chosen to develop an empirical model for CS during WEDM of Hastelloy C22 to provide a guideline to the potential users of the technique. This paper describes the response surface methodology (RSM) based mathematical modeling for average cutting speed. Furthermore, analysis of variance (ANOVA) was applied to find out significant process parameters and it was depicted that pulse on time and peak current were the major parameters affecting CS.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

scholarly journals Surface Roughness Prediction for Steel 304 In Edm Using Response Graph Modeling

2018 ◽  
Vol 14 (4) ◽  
pp. 115-124 ◽  
Author(s):  
Shukry H. Aghdeab ◽  
Nareen Hafidh Obaeed ◽  
Marwa Qasim Ibraheem
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Applied Current ◽  
Graph Modeling ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technique for metals removing which is relied upon the basic fact that negligible tool force is produced during the machining process. Also, electrical discharge machining is used in manufacturing very hard materials that are electrically conductive. Regarding the electrical discharge machining procedure, the most significant factor of the cutting parameter is the surface roughness (Ra). Conventional try and error method is time consuming as well as high cost. The purpose of the present research is to develop a mathematical model using response graph modeling (RGM). The impact of various parameters such as (current, pulsation on time and pulsation off time) are studied on the surface roughness in the present research. 27 samples were run by using CNC-EDM machine which used for cutting steel 304 with dielectric solution of gas oil by supplied DC current values (10, 20, and 30A). Voltage of (140V) uses to cut 1.7mm thickness of the steel and use the copper electrode. The result from this work is useful to be implemented in industry to reduce the time and cost of Ra prediction. It is observed from response table and response graph that the applied current and pulse on time have the most influence parameters of surface roughness while pulse off time has less influence parameter on it. The supreme and least surface roughness, which is achieved from all the 27 experiments is (4.02 and 2.12µm), respectively. The qualitative assessment reveals that the surface roughness increases as the applied current and pulse on time increases

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.

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy

2015 ◽  
Vol 231 (6) ◽  
pp. 956-970 ◽  
Author(s):  
Neeraj Sharma ◽  
Tilak Raj ◽  
Kamal Kumar Jangra
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Influence Of Process Parameters ◽  
Work Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Response Variables

NiTi is a shape memory alloy, mostly employed in cardiovascular stents, orthopedic implants, orthodontic wires, micro-electromechanical systems and so on. The effective and net shape machining of NiTi is very critical for excellent response of this material in medical and other applications. The present experimental work on wire electrical discharge machining process identifies the influence of process parameters that affect the cutting rate, dimensional shift and surface roughness while machining of porous nickel–titanium (Ni40Ti60) alloy. Porous Ni40Ti60 alloy was produced in-house using powder metallurgy technique. Response surface methodology–based central composite rotatable design has been used for the planning of experiments on wire electrical discharge machining. Empirical relations have been developed between the process parameters (pulse on-time, pulse off-time, servo voltage and peak current) and response variables. Desirability approach has been used for optimizing the three response variables simultaneously. Confirmation experiments were also performed at the optimized settings and reflect a close agreement between the predicted and experimental values (percentage error varies from −6.13% to +6.85%). Using wire electrical discharge machining, NiTi alloy can be machined easily and successfully in single-cutting operation, but after the first cut in wire electrical discharge machining, a surface projection appears on work surface which is the unmachined material on work surface.

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