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.

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.

Optimization and Prediction of Machining Responses Using Response Surface Methodology and Adaptive Neural Network by Wire Electric Discharge Machining of Alloy-X

2021 ◽  
Vol 1026 ◽  
pp. 28-38
Author(s):  
I. Vishal Manoj ◽  
S. Narendranath ◽  
Alokesh Pramanik
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Artificial Neural Network ◽  
Response Surface ◽  
Electric Discharge ◽  
Cutting Speed ◽  
Electric Discharge Machining ◽  
Surface Method ◽  
Wire Electric Discharge Machining ◽  
Pulse On Time

Wire electric discharge machining non-contact machining process based on spark erosion technique. It can machine difficult-to-cut materials with excellent precision. In this paper Alloy-X, a nickel-based superalloy was machined at different machining parameters. Input parameters like pulse on time, pulse off time, servo voltage and wire feed were employed for the machining. Response parameters like cutting speed and surface roughness were analyzed from the L25 orthogonal experiments. It was noted that the pulse on time and servo voltage were the most influential parameters. Both cutting speed and surface roughness increased on increase in pulse on time and decrease in servo voltage. Grey relation analysis was performed to get the optimal parametric setting. Response surface method and artificial neural network predictors were used in the prediction of cutting speed and surface roughness. It was found that among the two predictors artificial neural network was accurate than response surface method.

Effects of Machining Fluid on Electric Discharge Machining of SiC Ingot

2014 ◽  
Vol 778-780 ◽  
pp. 767-770 ◽  
Author(s):  
Norimasa Yamamoto ◽  
Satarou Yamaguchi ◽  
Tomohisa Kato
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Ion Exchange ◽  
Electric Discharge ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electric Discharge Machining ◽  
The Wire ◽  
Characteristic Features ◽  
First Time

Recently, ingots of silicon carbide have been adapted to be sliced by the wire-cut electrical discharge machining. Fast slicing, and the reduction in the loss are important for slicing of the wafer. In this paper, characteristic features of the electric discharge machining in the ion-exchange water and the fluorine-based fluid were compared for these improvement. The discharge was caused by a pulse voltage applied to a ingot of silicon carbide and the wire in machining fluid, and the slicing was proceeded. As a result, improvement of surface roughness and kerf loss was confirmed, for the first time. In addition, the improving methods for fast slicing were considered.

Effect of the Surfactant Concentration on Sinking Electric Discharge Machining Performance with Water-in-Oil Emulsion as Dielectric

2011 ◽  
Vol 189-193 ◽  
pp. 3153-3157
Author(s):  
Yan Zhen Zhang ◽  
Yong Hong Liu ◽  
Ren Jie Ji ◽  
Bao Ping Cai
Keyword(s):  
Physical Properties ◽  
Electric Discharge ◽  
Surfactant Concentration ◽  
Emulsion Stability ◽  
Experimental Results ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Oil Emulsion ◽  
The Stability ◽  
Water In Oil Emulsion

In this paper, the EDM performance of water-in-oil (W/O) emulsions dielectric with different surfactant concentration is investigated by correlated to its physical properties, such as viscosity and droplets size, which is predominantly determined by the surfactant concentration. Experimental results show that the stability of the W/O emulsions increases with increasing surfactant concentration, whereas the EDM performance deteriorates with increasing surfactant concentration. So, taking a comprehensively consideration of the emulsion stability and EDM performance, the concentration of surfactant must be appropriately selected.

Sign in / Sign up

Export Citation Format

Share Document