scholarly journals Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Energies ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 38 ◽  
Author(s):  
Misbah Niamat ◽  
Shoaib Sarfraz ◽  
Wasim Ahmad ◽  
Essam Shehab ◽  
Konstantinos Salonitis
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Multi Objective Optimization ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

2011 ◽  
Vol 189-193 ◽  
pp. 1393-1400 ◽  
Author(s):  
M.M. Rahman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

scholarly journals Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

2014 ◽  
Vol 2014 ◽  
pp. 1-16 ◽  
Author(s):  
Teepu Sultan ◽  
Anish Kumar ◽  
Rahul Dev Gupta
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Wear Rate ◽  
Response Surface ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electrode Wear Rate ◽  
Pulse On Time

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

Variation of electrode materials and parameters in the EDM of an AA7075-TiO2 composite

2021 ◽  
Vol 63 (2) ◽  
pp. 182-189
Author(s):  
Sivasamy Alagarsamy ◽  
Manickam Ravichandran
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrode Material ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Electrode Wear ◽  
Pulse On Time ◽  
Edm Process

Abstract The present study was carried out to analyze the effect of process parameters during EDM machining of AA7075-10 wt.-% TiO2 aluminum matrix composite (AMC). The composite was produced through stir casting. The EDM process parameters such as the electrode material (Cu, Br, EN-8), pulse current (5, 10 and 15 A), pulse ON time (300, 600 and 900 μs) and pulse OFF time (30, 60 and 90 μs) were chosen to study the effects on material removal rate, surface roughness and the electrode wear ratio. The experiment was carried out as per L27 orthogonal array based on Taguchi’s design of experiments. Signal-to-noise ratio and analysis of variance were used to identify the contribution of each input parameters on the output responses of the EDM process. The experimental results shows that pulse ON time and pulse current are the most significant factors for the material removal rate; pulse ON time and electrode material are the most influencing parameters for surface roughness and the electrode wear ratio.

Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites

2014 ◽  
Vol 941-944 ◽  
pp. 1973-1976
Author(s):  
B. Geetha ◽  
K. Ganesan
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Peak Current ◽  
Pulse On Time

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.

ELECTRICAL DISCHARGE MACHINING OF Al/7.5% Al2O3 MMCs USING ROTARY TOOL AND Al2O3 POWDER

2017 ◽  
Vol 24 (02) ◽  
pp. 1750018 ◽  
Author(s):  
SAEED DANESHMAND ◽  
BEHNAM MASOUDI ◽  
VAHID MONFARED
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Pulse On Time

Nowadays, composites are used in different parts of industries and it is one of the most important subjects. The most widely used reinforcements in metal matrix composites are Al2O3 and SiC fibers and particles which may be used in cutting-edge functional and structural applications of aerospace, defense, and automobile industries. Depending on the type of powder used, composite materials are difficult to machine by conventional cutting tools and methods. The most appropriate way for machining of these composites is electro discharge. For the reason of improving the surface quality, tool wear rate and material removal rate and reducing the cracks on the surface, Al2O3 powder was used. In this study, the effect of input parameters of EDM such as voltage, pulse current, pulse on-time and pulse off-time on output parameters like material removal rate, tool wear rate and surface roughness in both conditions of the rotary tool with powder mixed dielectric EDM and the stationary tool excluding powder mixed dielectric were investigated. The critical parameters were identified by variance analysis, while the optimum machining parameter settings were achieved via Taguchi method. Results show that using of powder mixed dielectric and rotary tool reduce the tool wear rate, surface roughness and the cracks on the surface significantly. It is found also that using of powder mixed dielectric and rotary tool improve the material removal rate due to improved flushing action and sparking efficiency. The analysis of variance showed that the pulse current and pulse on-time affected highly the MRR, TWR, surface roughness and surface cracks.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

scholarly journals Experimental Study During Electrical Discharge Machining of Reinforced Carbon Fiber Plastic Material

2021 ◽  
Vol 9 (8) ◽  
pp. 1445-1451
Author(s):  
Gaurav Pandey
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Wear Rate ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Fiber Composite ◽  
Electrode Wear ◽  
Machining Parameters

Abstract: The proper selection of machining conditions and machining parameter is an important aspect, before going to machine a carbon-fiber composite material by Die sinking electrical discharge machining (EDM). Because these conditions will determine such important characteristics as; Material removal rate (MRR), Electrode wears rate (EWR), and Surface roughness (R). The purpose of this work is to determine the optimal values of machining parameters of electrical discharge machine, while machining carbon-fiber-composite with copper electrode. The work has been based on the affect of four design factors: pulse current(Ip) supplied by power supply system of electrical discharge machine (EDM), pulse-on-time(TON), gap voltage(Vg) and duty cycle () on such characteristic like material removal rate (MRR), electrode wear rate(EWR), and surface roughness(Ra) on work-piece surface. This work has been done by means of the technique of design of experiment (DOE), which provides us to perform the above-mentioned analysis with small number of experiments. In this work, a L9 orthogonal array is used to design the experiment. The adequate selection of machining parameters is very important in manufacturing system, because these parameters determine the surface quality and dimensional accuracy of the manufactured part. The optimal setting of the parameters are determined through experiments planned, conducted and analyzed using the Taguchi method. It is found that material removal rate (MRR) reduces substantially, within the region of experimentation, if the parameters are set at their lowest values, while the parameters set at their highest values increases electrode wear rate (EWR). Keywords: EDM, Material removal rate, Surface roughness, Tool wear rate,

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

scholarly journals Experimental Investigation of Edm Die Sinking Process Parameters on Aluminium Alloy 5083 Using Design of Experiment

2017 ◽  
Vol 4 (1) ◽  
pp. 138-144
Author(s):  
Wahaizad Safiei ◽  
Muhamad Ridzuan Radin Muhamad Amin
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Design Of Experiment ◽  
Material Removal ◽  
Removal Rate ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time

In this paper, the results of surface roughness (Ra) and material removal rate (MRR) are presented based on experimental studies of Electrical Discharge Machining (EDM) process parameters. Pulse ON time, pulse OFF time, peak current, gap voltage and jump speed are the selected input parameters and the experiments were conducted with Aluminium Alloy 5083 as a workpiece, copper as an electrode and the response variables are surface roughness (Ra) and material removal rate (MRR). Design of Experiment and Analysis of Variance (ANOVA) were applied to identify the optimum settings.The result shows that the significant factors for the value of surface roughness (Ra) and material removal rate (MRR) are pulses ON time and peak current.

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