scholarly journals A STUDY ON CAPABILITIES OF DIFFERENT ELECTRODE MATERIALS DURING ELECTRICAL DISCHARGE MACHINING (EDM)

2017 ◽  
Vol 18 (2) ◽  
pp. 189-195
Author(s):  
Muataz Hazza Faizi Al Hazza
Keyword(s):  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Desirability Function ◽  
304 Stainless Steel ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Electrode Wear ◽  
Copper Aluminum ◽  
Full Factorial

Electrode material inelectro discharge machining EDM process plays an important role in terms of material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). The purpose of this research is to investigate the capability of different electrode materials: copper, aluminum and graphite in EDM of AISI 304 stainless steel as a work piece. The research focuses on three current settings: 2.5A, 4.5A and 6.5A using kerosene as dielectric fluid. The experiment is planned and analyzed using full factorial of the experimental design using response surface methodology (RSM). two outputs have been investigated: MRR and EWR. The results indicated that the responses increased with the increase in current. Finally the desirability function method have been used to determine the optimum values. The resulat show that the maximum MRR and  the minimum EWR were achieved by using graphite electrode at current 6.5A.

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.

Experimental Analysis of Canola Oil as Dielectric Fluid in Electric Discharge Machining of AISI D2 Steel

2020 ◽  
Vol 978 ◽  
pp. 49-54
Author(s):  
Kusumba Mangapathi Rao ◽  
D. Vinay Kumar ◽  
K.Chandra Shekar ◽  
Balasubramaniyan Singaravel
Keyword(s):  
Electric Discharge ◽  
Canola Oil ◽  
Removal Rate ◽  
Dielectric Liquid ◽  
Dielectric Fluid ◽  
Work Piece ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Plasma Generation ◽  
Aisi D2

Electric Discharge Machining (EDM) is a thermo-electrical disintegration process, utilized to cut hard materials into complex shapes. In EDM, the three vital components are work-piece material, electrode material and dielectric liquid. The significant function of the dielectric fluid is to produce a breakdown voltage for creating a spark between work-piece and electrode. This spark creates ionization by plasma generation and it expels the material from work-piece. In most cases, hydrocarbon-based dielectric liquid is preferred in the EDM process. This kind of dielectric liquid generates hazardous gases which are harmful to people, environment and ecological balances. In this experiment, Canola oil is utilized and the outcomes are compared. The input parameters are Pulse on/off time, current and gap voltage. Copper, Brass and Tungsten-Copper (Alloy) are used as electrodes. The output values from the experiments are Surface Roughness (SR), Electrode Wear Rate (EWR) and Material Removal Rate (MRR). The outcomes demonstrated that Canola oil-based dielectric fluid has comparable properties of conventional based dielectric fluid. This Canola based dielectric gives more prominent MRR value than EDM oil-based dielectric liquid and furthermore higher EWR and SR values are recorded. The proposed Canola oil-based dielectric fluid is biodegradable and has improved suitability in machining.

Analysis of Micro-Pin Manufacturing Using Inverse Slab Electrical Discharge Milling (ISEDM) Process

2011 ◽  
Vol 496 ◽  
pp. 247-252 ◽  
Author(s):  
Ruben Gil ◽  
J.A. Sánchez ◽  
N. Ortega ◽  
S. Plaza ◽  
B. Izquierdo ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Work Piece ◽  
Electrode Wear ◽  
Pulse Off Time

Abstract. This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), using a conventional EDM machine and graphite electrode. The effect of pulse off-time, work piece final diameter and machining length on material removal rate, electrode wear ratio, radial accuracy and surface roughness has been quantified. From the study, optimum strategies that involve the use of different EDM regimes for achieving the optimum requirements can be defined. Micro-pins of 0.3 mm diameter with aspect ratio as high as 100:1 have been successfully manufactured.

Effect of low-frequency vibrations on MRR, EWR and Ra in powder-mixed electrical discharge machining

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040153
Author(s):  
Quang Dung Le ◽  
Huu Phan Nguyen ◽  
Tien Long Banh ◽  
Duc Toan Nguyen
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Low Frequency ◽  
Lower Surface ◽  
Dielectric Fluid ◽  
Electrode Wear ◽  
Maximum Increase ◽  
Lower Electrode ◽  
Powder Mixed Edm

In this study, the effects of low-frequency vibrations on machining SKD61 steel workpiece in electrical discharge machining (EDM) with titanium powder-mixed dielectric fluid were investigated. The results showed that the vibrations incorporated into the workpiece in powder-mixed EDM (PMEDM) led to significant improvement in machining efficiency. The material removal rate had the maximum increase of 141.7% with 70.2% of lower electrode wear rate and 69.9% of lower surface roughness. Hence, it is proved that the effectiveness of vibration in PMEDM can be improved.

Analysis of Electrical Discharge Machining Using Water as Dielectric and Diverse Electrode Materials

2008 ◽  
Author(s):  
Hugo Medellin ◽  
Aaro´n Flores ◽  
Jorge Morales ◽  
Alonso de la Garza
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Low Carbon Steel ◽  
Electrode Wear ◽  
Low Carbon ◽  
Source Voltage ◽  
Materials Used ◽  
Edm Process

This paper presents an experimental investigation carried out to study the performance of electrical discharge machining (EDM) using water as dielectric. This experimentation was performed using different types of water as dielectric, several electrode materials and two different workpiece materials. The electrode materials used in the experimentation were bronze, brass, copper, aluminium and steel; and the workpiece materials used were ASTM A36 mild (low-carbon) steel and D-2 tool steel. A new desktop size EDM machine to perform the experiments was designed and is presented in this paper. After performing the experimentation, the results have shown that the best EDM performance is achieved with brass and bronze electrodes using a mixture of 75% tap and 25% deionised water as dielectric. The results also indicate that the material removal rate and the electrode wear are proportional to the source voltage used in the EDM process. Finally, a forming die with a complex shape used in a jewellery industry, was manufactured using the EDM system presented in this paper.

Machining performance of 3D-printed ABS electrode coated with copper in EDM

2019 ◽  
Vol 25 (7) ◽  
pp. 1224-1231 ◽  
Author(s):  
Ujwal A. Danade ◽  
Shrikant D. Londhe ◽  
Rajesh M. Metkar
Keyword(s):  
Fused Deposition Modeling ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Work Piece ◽  
Electrode Wear ◽  
Machining Performance ◽  
Solid Electrode ◽  
Content Type ◽  
Fused Deposition ◽  
Pulse On Time

Purpose Rapid tooling (RT) technique using rapid prototyping (RP) process has been looked upon as an approach which reduces time and cost of production. This study aims to produce electrode for electrical discharge machining (EDM) from acrylonitrile butadiene styrene (ABS) material using the fused deposition modeling (FDM) process of RP. The electrode is coated with copper to a depth of 1 mm by using electroplating to make it conductive. This electrode is termed as RP electrode. The performance of RP electrode having square shape is compared with that of solid electrode of copper having identical size. Design/methodology/approach In this study, the work piece material is chosen to be titanium Grade-V alloy (Ti-Al6-V4). The input parameters on the EDM machine such as discharge current, pulse on time and voltage are studied, and experiments are designed using the Taguchi method. Findings The results pertaining to the material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra) are reported. It is found that the performance of a coated RP electrode is equally satisfactory when compared with that of a solid electrode. Originality/value This paper reports the machining performance of a square-shaped ABS electrode coated with copper. This technique, particularly when the electrode is of intricate shape, saves on cost and time of production of electrode to be used for EDM.

A Study Comparative of Cu and Cu-Zn Electrode during Electrical Discharge Machining on Martensitic Stainless Steel AISI 410

2014 ◽  
Vol 931-932 ◽  
pp. 327-332 ◽  
Author(s):  
Rattikorn Saodaen ◽  
Pichai Janmanee ◽  
Somchai Wonthaisong ◽  
Apiwat Muttamara
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Open Circuit ◽  
Electrode Wear ◽  
Workpiece Material ◽  
Steel Aisi ◽  
Open Circuit Voltages

The objective of this research is to study comparisons of Cu and CuZn electrodes, during Electrical Discharge Machining (EDM) of martensitic stainless AISI 410. The workpiece material was a rectangular plate, measuring 30x50x5 mm. The conditions of the EDM process were 3.0mm depth and 2.0 mm diameter, with variables of parameter being: currents, on/off-times and open circuit voltages of spark. Evaluation of the electrical discharge was conducted using Material Removal Rate (MRR), Electrode Wear Ratios (EWR) and Arithmetical Mean Roughness (Ra), respectively. The results found that CuZn electrode materials provide higher MRR and EWR than electrode materials of Cu. Also, when considering the melting of white layer, initial melts found that the white layer surface material is also good for the integrity of the state park, and it was additionally also found that when the current level increases, then that will rise accordingly.

Effects of Cu-Zn-Ni Electrode during EDM of SUS 304 Material

2014 ◽  
Vol 590 ◽  
pp. 202-206
Author(s):  
Pichai Janmanee ◽  
Suppawat Chuvaree ◽  
Jamkamon Kamonpong
Keyword(s):  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Structural Features ◽  
Electrode Wear ◽  
Element Analysis ◽  
Wear Ratio ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

In this study, experiments were performed to study the effects of electrode materials mixed with nickel in electrical discharge machining (EDM) of SUS 304 material. Experiments were constructed using parameters consisting of pulse-on time, pulse-off time, discharge current and electrode polarity, respectively. The analysis of structural features of the surface was accomplished using a scanning electron microscope (SEM) as well as an element analysis created on the surface, after the EDM process, by using Energy-dispersive x-ray spectroscopy (EDS). The results of the experiments found that nickel elements in the electrode material have an effect on the working performance of material removal rate and electrode wear ratio. The electrode wear ratio reduces when nickel elements increase. Moreover, the surface roughness had the lowest level at electrode 15 % nickel element. Thus, electrode wear during the EDM process of nickel element from electrodes and other elements, combined with surface metalworking, becomes a recast layer of nickel.

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.

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