scholarly journals Improving the Performance of EDM through Relief-Angled Tool Designs

2020 ◽  
Vol 10 (7) ◽  
pp. 2432 ◽  
Author(s):  
Nadeem Ahmad Mufti ◽  
Madiha Rafaqat ◽  
Naveed Ahmed ◽  
Muhammad Qaiser Saleem ◽  
Amjad Hussain ◽  
...  
Keyword(s):  
Tool Wear ◽  
Electric Discharge ◽  
Cutting Tools ◽  
Tool Design ◽  
Electric Discharge Machining ◽  
Machining Time ◽  
Response Characteristics ◽  
Relief Angle ◽  
Machining Rate ◽  
Conventional Tool

Among the family of carbides, tungsten carbide (WC) and its variants have extensive use in numerous applications including cutting tools, dies, and many wear resistant parts. Such applications need machining of WC, which is famously considered as challenging due to high tool wear mainly in traditional machining. Sinking electric discharge machining (EDM) can be considered as a suitable alternate but the low machining rate of EDM, with conventional tool design, poses limitations. In this research, the conventional tool design is modified by providing relief angles to the tool electrodes. The relief-angled tool electrodes are first time introduced in this research to machine through holes. The role of the relief angle during EDM has been investigated in terms of six response characteristics, i.e., machining time, hole taper angle, radial overcut at the hole entrance, radial undercut at the hole exit, longitudinal tool wear, and roughness of inside hole surfaces. The performance of the relief-angled electrodes is found to be significantly better than the performance of conventional cylindrical tool. In addition to improvements in other responses, a 49% reduction in the machining time has been realized by the use of relief-angled electrode indicating a worthwhile contribution in the field of electric discharge machining.

scholarly journals Optimization of Machining Variables in Electric Discharge Machining Using Stainless Steel 317 in Full Factorial Method

2020 ◽  
Vol 22 (1) ◽  
pp. 105-118 ◽  
Author(s):  
S. Nandhakumar ◽  
S. Sathish Kumar ◽  
K. Sakthivelu
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electric Discharge ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Electric Discharge Machining ◽  
Machining Time ◽  
Input Variables

AbstractElectric Discharge Machining (EDM) is a non-conventional machining process and has a larger extent of application in manufacturing industry due to its accuracy. EDM simply uses electrical spark between the tool and workpiece in presence of dielectric medium to erode the workpiece in controlled manner. Improving the material removal rate and decreasing the tool wear rate (TWR), achieving higher surface finish, reducing machining time and enhancing dimensional accuracy are the major areas of focus in electrical discharge machining (EDM) process of SS 317 grade steel. In this research work effort to reduce the tool wear rate is concentrated by comparing the machining performance of two distinct electrodes namely copper and brass. Each electrode has their unique machining capabilities and the experimental results were compared in-terms of tool wear rate (TWR), Metal Removal Rate (MRR) and Machining Time (TM). Input variables were optimized based on the experimental output responses to achieve optimal level of input variables.

scholarly journals EDM of D2 Steel: Performance Comparison of EDM Die Sinking Electrode Designs

2020 ◽  
Vol 10 (21) ◽  
pp. 7411 ◽  
Author(s):  
Madiha Rafaqat ◽  
Nadeem Ahmad Mufti ◽  
Naveed Ahmed ◽  
Abdulrahman M. Alahmari ◽  
Amjad Hussain
Keyword(s):  
Surface Roughness ◽  
Electric Discharge ◽  
Performance Comparison ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Machining Time ◽  
Taper Angle ◽  
Radial Overcut ◽  
Circular Holes ◽  
Machining Rate

Electric discharge machining (EDM) of tool steel (D2 grade) has been performed using different tool designs to produce through-holes. Machining performance has been gauged with reference to machining time, hole taper angle, overcut, and surface roughness. Inaccuracies and slow machining rate are considered as the most common limitations of the electric discharge machining (die-sinking). Traditionally, a cylindrical tool is used to form circular holes through EDM. In this study, the hole formation is carried out by changing the tool design which is the novelty of the research. Two-stage experimentation was performed. The newly designed tools substantially outperformed a traditional cylindrical tool, especially in terms of machining time. The main reason for the better machining results of modified tools is the sparking area that differs from the traditional sparking. Comparing against the performance of a traditional cylindrical tool, the newly designed tools offer a considerable reduction in the machining time, radial overcut, and roughness of the inside surfaces of machined holes, amounting to be approximately 50%, 30.6%, and 38.7%, respectively. The drop in the machining time along with a condensed level of radial overcut and surface roughness can shrink the EDM limitations and make the process relatively faster with low machining inaccuracies.

Study the Effects of Dielectric Type on the Machining Characteristics of γ-Ti Al in Electrical Discharge Machining

2017 ◽  
Vol 33 ◽  
pp. 40-49
Author(s):  
Mohammad Reza Shabgard ◽  
Hossein Faraji ◽  
Behnam Khosrozade ◽  
Hadi Eivazi-Bagheri ◽  
Keivan Amini
Keyword(s):  
Intermetallic Compound ◽  
Tool Wear ◽  
Electric Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Deionized Water ◽  
Surface Cracks ◽  
Electric Discharge Machining ◽  
Tool Wear Ratio

The current study surveys the results of using deionized water and kerosene as dielectrics in the machining outputs of γ-TiAl intermetallic compound obtained in electric discharge machining. Influences of these different dielectrics properties on machining speed, tool wear, surface cracks and roughness were compared. Scanning electron microscopy micrographs were prepared to investigate influences of dielectrics on the surface characteristics of electrically discharged samples. Results indicate which by kerosene dielectric; the material removal rate (MRR) is further compared to another one. But deionized water as dielectric causes higher tool wear ratio than kerosene dielectric. Electrical discharged samples in deionized water have higher surface roughness, in addition it contains surface cracks, whereas kerosene dielectric results better surface finish in low pulse current. According to XRD spectra electric discharge machining in deionized water and kerosene dielectrics produces Ti3 Al intermetallic compound on the produced surface.

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