scholarly journals The analysis of material removal rate of WEDM miniature gears

2021 ◽  
Vol 41 (3) ◽  
Author(s):  
Ashish Goyal ◽  
Vyom Singh ◽  
Abhishek Patel
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spur Gear ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Gear fabrication in wire electrical discharge machining (WEDM) plays an important role in manufacturing industries. This paper describes the analysis and optimization of process parameters for the fabrication of spur gear on brass spur gear on brass workpiece (10cmx15cmx6mm) material by wire EDM process. The experiments were performed by using the design of experiment (DoE) approach and the material removal rate (MRR) was analyzed by response surface methodology technique. The effect of input parameters i.e. pulse on time, pulse off time and feed rate on MRR has been investigated. The surface geometry of the gears has been analysed by the Scanning Electron Microscopy (SEM). This study found that 0.4 μs for pulse on time, 60 μs for pulse-off time and 6 mm/min for feed rate provides improved material removal rate. The analysis of variance shows that pulse on time and feed rate are the significant parameters for the wire EDM process. The SEM image exhibits the capability of WEDM to machined miniature gear with a uniform distribution of regular-shaped craters and defect-free flank surface.

Parameter Design of EDM Process to Optimize Surface Roughness and Material Removal Rate Using Taguchi Method

2021 ◽  
Vol 1028 ◽  
pp. 391-396
Author(s):  
Muhammad Firly Firmansyah ◽  
Suwarno Suwarno ◽  
Yanuar Rohmat Aji Pradana ◽  
Suprayitno Suprayitno
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Material Removal ◽  
Removal Rate ◽  
Parameter Design ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Electrical discharge machining (EDM) is a non-conventional process that is widely used for high-precision machining, complex product shapes, and high hardness materials. The EDM mechanism is based on the thermoelectric energy between the electrode and the workpiece. The EDM process has many parameters that can be adjusted, such as discharge current, voltage, pulse on time, pulse off time, electrode polarity, workpiece material, electrode material, dielectric fluid type, flushing pressure, flushing direction and flushing method. This study aims to find the parameters of the EDM process to optimize its productivity indicated by material removal rate (MRR) and its quality indicated by surface roughness of SS-316 material. The varied parameters were discharge current, pulse on time, and pulse off time with 3 levels for each parameter. Fractional orthogonal array L9 were applied for three 3-level variables. Performance fluctuation due to noise factors were simply approximated by 3 replicating measurements to estimate mean and standard deviation. Taguchi S/N ratio were adopted as robustness index for the optimum parameter design. The optimization results show that the discharge current 30A, pulse on time 100μs, and pulse off time 8μs are the optimum for MRR. As for surface roughness, the discharge current is 10A, pulse on time is 100μs, and pulse off time is 8μs. The only different of EDM parameter for optimum MRR and optimum Ra is discharge current.

scholarly journals Multi- Response Optimization of Wire EDM Process Parameter on Aluminium Alloy (5086)

2020 ◽  
Vol 10 (1) ◽  
pp. 224-229
Keyword(s):  
Aluminium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Control Parameter ◽  
Removal Rate ◽  
Response Optimization ◽  
High Pulse ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, the effect of process parameters on material removal rate during the machining of aluminium alloy (5086) with WEDM is studied. The four control parameter were selected i.e pulse on time (TON), pulse off time (TOFF), peak current (IP), and spark gap voltage (SV) to investigate their effects on material removal rate (MRR). Each control parameter had three levels. Total 27 experiments were done with a zinc coated brass wire of diameter 0.25 mm. Taguchi L9 orthogonal array technique was used for the experiment. ANOVA was used to find out the significance of control parameters and their contribution on MRR. It was found that maximum material removal rate was 41.52 mm3 /min which was due to high pulse on time and low pulse off time.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method

2015 ◽  
Vol 799-800 ◽  
pp. 343-350
Author(s):  
Rahul Shukla ◽  
Brajesh Kumar Lodhi
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Kerf Width ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

scholarly journals A Study on Optimization of Process Parameters in Machining of Bronze using Wire-EDM

2021 ◽  
pp. 484-493
Author(s):  
Gajanan Kamble ◽  
Dr. N. Lakshamanaswamy ◽  
Gangadhara H S ◽  
Sharon Markus ◽  
N. Rajath
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time

Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf width were studied against the process parameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP). The machining parameters for wire EDM were optimized for achieving the combined objectives. As there are three input parameters 27 experiments is carried out and full factorial is used. Optimized parameters were found using (ANOVA) and the error percentage can be validated and parameter contribution for the Material removal rate (MRR) and Surface roughness were found.

scholarly journals Parameter Optimization of Wire EDM for H-13 Tool Steel

2018 ◽  
Vol 8 (01) ◽  
Author(s):  
Satish Giduturi ◽  
Ashok Kumar
Keyword(s):  
Tool Steel ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Wire Feed

Wire Electrical Discharge Machining (WEDM) is a widely accepted non-traditional material removal process used to manufacture components with intricate shapes and profiles. It is considered as a unique adaptation of the conventional EDM process, which uses an electrode to initialize the sparking process. H13 Hot Work Tool Steel has high hot tensile strength, hot wear-resistance and toughness. Good thermal conductivity and insensitiveness to hot cracking, making it suitable not only for hot die applications but also plastic moulds. In this study, it is found that most predominant factors for the maximum material removal rate which is 22.21 mm3/min are current which was found to be 200A and Pulse ON Time 125 µs, however rest four factors (voltage 20V, pulse off time 40µs, wire tension 8N and wire feed 7mm/min) has less impact as compare to the predominant factors. The most predominant factors for Minimum surface roughness which is 0.89µm are wire tension 10N, pulse on time 115µs and servo voltage 60V. However, rest three factors pulse off time 60 µs, peak current 140 A and wire feed 7mm/min has less impact as compare to the predominant factors.

Optimization of Material Removal Rate in EDM Using Taguchi Method

2012 ◽  
Vol 626 ◽  
pp. 270-274 ◽  
Author(s):  
Milan Kumar Das ◽  
Kaushik Kumar ◽  
Tapan K. Barman ◽  
Prasanta Sahoo
Keyword(s):  
Material Removal Rate ◽  
Discharge Current ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter ◽  
Off Time

This paper presents an investigation on the effect and optimization of machining parameters on material removal rate (MRR) in electrical discharge machining (EDM) of EN31 tool steel. For the experiment, four process parameters viz. pulse on time, pulse off time, discharge current and voltage are considered. The settings of machining parameters are determined by using Taguchis orthogonal array (OA). L27 orthogonal array (OA) is considered for the study. The level of importance of the machining parameters on MRR is determined by analysis of variance (ANOVA) test. The optimum machining parameter combination is obtained by the analysis of signal-to-noise (S/N) ratio. The analysis shows that discharge current has the most significant effect on MRR followed by pulse off time and voltage. It is seen that with an increase in discharge current and pulse off time, MRR increases in the studied range. The methodology described here is expected to be highly beneficial to manufacturing industries.

Parametric effect on material removal rate and surface roughness of electrical discharge machined magnesium alloy

2021 ◽  
Vol 118 (6) ◽  
pp. 615
Author(s):  
Narayanasamy Ananthi ◽  
Uthirapathi Elaiyarasan ◽  
Vinaitheerthan Satheeshkumar ◽  
Chinnamuthu Senthilkumar ◽  
Subbarayan Sathiyamurthy ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Current Pulse ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Damping Capacity ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Magnesium and its alloys play a vital role in various applications such as automobile, aircraft, biomedical and military etc. Mg alloys have superior characteristics such as light weight, high strength, good damping capacity and easily castability etc. Eventhough it has attractive range of properties, the machining of magnesium alloys using conventional machining methods is difficult. To overcome that issue, non traditional machining is considered as a potential process. EDM is an electro thermal process extensively used for machining hard materials. In this investigation, the ZE41A magnesium alloy is machined using EDM with copper electrode. In order to improve surface characteristics such as material removal rate (MRR) and surface roughness (SR), various parameters namely current, pulse on time and pulse off time were selected. The regression values of MRR and SR are 97.20% and 99.62% respectively indicating an empirical relationship between the parameters and responses. Pulse off time was found as a significant parameter on the response followed by pulse on time and current. MRR and SR increased with increasing current, pulse on time and pulse off time. At a current of 5A, the produced spark density is high so that the removed quantity of material from the workpiece is high. At a pulse on time of 95 μs, the spark intensity is high affecting the local temperature in the machined zone, and hence MRR increases. SR drastically increases at increasing current. At higher current, large size crater are observed on the machined surface that made the surface rough, and hence SR increases.

Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
G. Ramanan ◽  
R. Elangovan
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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