scholarly journals Investigation of the Effect of Nano Powder Mixed Dielectric on EDM Process

2020 ◽  
Vol 38 (3A) ◽  
pp. 295-307
Author(s):  
Rasha R. Elias
Keyword(s):  
Aluminum Oxide ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Dielectric Fluid ◽  
Tool Wear Rate ◽  
Powder Concentration ◽  
Nano Powder ◽  
Edm Process

In this paper, Artificial Neural Network was adopted to predict the effect of current, the concentration of aluminum oxide (Al2O3) and graphite Nanopowders in dielectric fluid for the machining of Carbon steel 304 using Electrical Discharge Machining (EDM). The process variables were utilized to find their effect on Material Removal Rate (MRR), Surface Roughness (SR), and Tool Wear Rate (TWR). It was revealed from the experimental work that the addition of aluminum oxide and graphite Nanopowders into dielectric fluid maximizing MRR, minimized the SR and TWR at various variables. Minitab software was used in the design of experiments. Analysis of the process outputs of EDM indicates that graphite powder concentration greatly influencing SR also the discharge current whereas the current and Nanopowders concentration has more percentage of influence on the TWR and MRR.

Surfactant and graphite powder–assisted electrical discharge machining of titanium alloy

2016 ◽  
Vol 231 (4) ◽  
pp. 641-657 ◽  
Author(s):  
Murahari Kolli ◽  
Adepu Kumar
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Recast Layer ◽  
Dielectric Fluid ◽  
Recast Layer Thickness

Surfactant and graphite powder–assisted electrical discharge machining was proposed and experiments were performed on titanium alloy in this investigation. Analysis was carried out to observe changes in dielectric fluid behaviour, material removal rate, surface roughness, recast layer thickness, surface topography and energy-dispersive X-ray spectroscopy. It was found out that the addition of surfactant to dielectric fluid (electrical discharge machining oil + graphite powder) improved the material removal rate and surface roughness. It was noticed to have reduced the recast layer thickness and agglomeration of graphite and sediment particles. Biface material migrations between the electrode and the workpiece surface were identified, and migration behaviour was powerfully inhibited by the mixing of surfactant. Surfactant added into dielectric fluid played an important role in the discharge gap, which increased the conductivity, and suspended debris particles in dielectric fluid reduced the abnormal discharge conditions of the machine and improved the overall machining efficiency.

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.

Electro-Discharge Machining of Aluminum Alloy with Nickel Powder-Mixed Dielectric

2018 ◽  
Vol 3 (2) ◽  
pp. 49
Author(s):  
Srinivasa Rao P ◽  
Eshwara Prasad K
Keyword(s):  
Material Removal ◽  
Nickel Powder ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Nickel Concentration ◽  
Powder Concentration ◽  
Electro Discharge Machining ◽  
Nickel Powders ◽  
Electrode Discharge ◽  
Edm Process

Powder-mixed dielectric fluid is one of the innovations of electrode-discharge machining (EDM) which seeks to improve the process outputs by addition of Nickel powders to the dielectric during machining. In the present study, the influence of Nickel powder in kerosene dielectric fluid on EDM process outputs was investigated.  Experiments were conducted with the outputs as material removal rate (MRR) and surface roughness(Ra). During the EDM, the discharge current was varied between 3 and 15 A, while powder concentration ranges between 2 and 10 g/l.  Results indicate that the highest MRR of  39.888 mm3 /min was obtained with Nickel powder concentration of 6 g/l at the current of  9A, where as the lowest SR of  3.397 μm was obtained with Nickel concentration of 3 g/l at the current of 3A.

Performance of Electrical Discharge Milling and Sinking in Micro Graphite Powder Mixed Dielectric

2017 ◽  
Vol 900 ◽  
pp. 127-130 ◽  
Author(s):  
Houriyeh Marashi ◽  
Ahmed A.D. Sarhan ◽  
Ibrahem Maher ◽  
Mohd Hamdi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
High Hardness ◽  
Graphite Powder ◽  
Dielectric Fluid ◽  
Machined Surface ◽  
Performance Factors ◽  
Powder Concentration

Electrical discharge machining (EDM) is a non-conventional machining technique that is well-known for use in fabricating dies and molds owing to machinability of high hardness materials. Although the electro-thermal mechanism of EDM offers many advantages over other available machining methods, its sluggish nature limits the wide application of such machines for mass production. In this research, adding graphite powder to dielectric is proposed to improve EDM performance factors. Material removal rate (MRR) and average surface roughness (Ra) have been monitored and evaluated after addition of graphite powder to dielectric in electrical discharge milling and sinking. It is found that the presence of powder particles in dielectric fluid enhances the MRR steadily up to ~11 and ~17% for milling and sinking process, respectively. Moreover, the highest enhancement if Ra is ~31% at 1g/l graphite powder concentration for electrical discharge milling and up to ~11% for sinking process. Field emission scanning electron microscopy (FESEM) is used to inspect the machined surfaces. The surfaces machined with graphite powder mixed appear significantly unlike the surfaces machined in pure dielectric. Adding powder to dielectric is found to increase the machined surface hardness by ~26%, from 240 to 302 HV.

scholarly journals Investigation into effects/Investigating the effects of titanium powder concentrations mixed in dielectric fluid on material machining removal and surface roughness of SKD61 steel after electrical discharge machining by reverse electrode polarity

2015 ◽  
Vol 18 (2) ◽  
pp. 43-51
Author(s):  
Long Tien Banh ◽  
Cuong Ngo ◽  
Phan Huu Nguyen
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Material Removal ◽  
Titanium Powder ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Electrode Polarity ◽  
Edm Process

Electrical discharge machining (EDM) has found widespread applications in tool , mold and aerospace industries. Therefore, enhancement of the quality of the EDM process has become a major research concern. In this paper, the effect of various titanium powder concentrations on the Material Removal Rate (MRR), tool wear rate (TWR), surface roughness (Ra) in powder mixed electrical discharge machining (PMEDM) have been studied. The workpiece is SKD61steel and electrode made from copper with reverse polarity were used in experimental study. The results showed that titanium powder mixed into the dielectric fluid of EDM can enhance MRR without increasing TWR and Ra.

Electro-Discharge Machining of SUS 304 Stainless Steel with TaC Powder-Mixed Dielectric

2012 ◽  
Vol 576 ◽  
pp. 72-75 ◽  
Author(s):  
Zakaria Mohd Zain ◽  
Mohammed Baba Ndaliman ◽  
Ahsan Ali Khan ◽  
Mohammad Yeakub Ali
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Dielectric Fluid ◽  
Micro Hardness ◽  
Powder Concentration ◽  
Electro Discharge Machining ◽  
Powder Addition ◽  
Edm Process

Powder-mixed dielectric fluid is one of the innovations of electro-discharge machining (EDM) which seeks to improve the process outputs by addition of powders to the dielectric during machining. In the present study, the influence of TaC powder in kerosene dielectric fluid on EDM process outputs was investigated. Experiments were conducted with the outputs as material removal rate (MRR), surface roughness (Ra) and micro-hardness. During the EDM, the discharge current was varied between 2.5 and 6.5 A, while powder concentration ranges between 5.0 and 15.0 g/l. Results indicate that the highest MRR of 0.38 g/min was obtained with TaC concentration of 15 g/l at the current of 6.5 A. TaC powder addition does not affect both the MRR and Ra at lower current. However, the level of micro-hardness attained was influenced by TaC powder concentration in dielectric fluid, the highest being 1,040 Hv with 5.0 g/l at the current of 2.5 A.

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).

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

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).

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