scholarly journals Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1223
Author(s):  
Emil Evin ◽  
Miroslav Tomáš ◽  
Jozef Kmec
Keyword(s):  
Body Parts ◽  
Peak Voltage ◽  
Aluminum Sheets ◽  
Heat Treated ◽  
Output Characteristics ◽  
High Degree ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Peak Count

Exterior car-body parts are made of steel or aluminum sheets. Their formability and appearance after painting depends not only on the mechanical properties but also on their surface texture. The surface roughness characteristics, the roughness average Ra and the peak count Pc per centimeter depend on the texture of rolling mill’s finishing rollers, their wear and the degree of removal by the rolling mill. The research was carried out on heat-treated finishing rollers on the surface of which a controlled texture was created by changing the electro-discharge texturing (EDT) parameters. Parameters and the number of electro-discharge texturing experiments were optimized using full four-factor experiment techniques at the upper and lower levels of the parameters in the form of 24. The significance of the impact of individual EDT parameters and their interactions was identified based on the variance results. The ANOVA variance analysis results confirmed that the roughness Ra and the peak count Pc depend primarily on peak current (Ip), discharge peak voltage (Up), pulse on time (Pont) and pulse off time (Pofft). Optimization of the effect of the above parameters on the target roughness RaT,FR values and the peak count PcT,FR of finishing rollers was performed by the response surface methodology (RSM). Obtained regression models describe relationships between the input parameters of the electro-discharge texturing of finishing rollers and the output characteristics of the RaT,FR and the PcT,FR texture to a very high degree. The reliability of the electro-discharge texturing process of working rollers was assessed using the process capability index Cpk.

scholarly journals Optimisation of EDM Parameters for Cryogenically Treated EN31 Steel with Copper Tool

2021 ◽  
pp. 204-229
Author(s):  
Dillen Henry C ◽  
Goyal Sai Y ◽  
Mr. D. Sakthivel
Keyword(s):  
Removal Rate ◽  
Cryogenic Treatment ◽  
Tool Geometry ◽  
Hard Material ◽  
Workpiece Material ◽  
Heat Treated ◽  
Machining Operations ◽  
Heat Resistant Steels ◽  
Pulse On Time ◽  
Pulse Off Time

EDM has been replacing drilling, milling, grinding, and other traditional machining operations and is now a well-established machining option in many manufacturing industries throughout the world and is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat-treated tool steels, composites, superalloys, ceramics, carbides, heat resistant steels, etc. During machining done over EDM machine, with the workpiece, even the tool wears out. This tool wear is not desired as it changes the tool geometry. To overcome this hurdle, cryogenic treatment is carried out for workpiece material before machining. This report presents the optimization of EDM process parameters such as pulse on-time (Ton), pulse off-time (Toff), and Current (I) to obtain the greatest material removal rate (MRR) and less surface roughness (Ra) of EN31 steel with copper as the working electrode for machining.

scholarly journals Electrical Discharge Machining of SiC Reinforced 6061-T6 Aluminum Alloy Surface Composite Fabricated by Friction Stir Processing

2021 ◽  
Vol 309 ◽  
pp. 01044
Author(s):  
Murahari Kolli ◽  
Devaraju Aruri ◽  
Saikumar Gadakary ◽  
Satyanarayana Kosaraju
Keyword(s):  
Friction Stir Processing ◽  
Removal Rate ◽  
Alloy Surface ◽  
Aluminum Surface ◽  
Machining Parameters ◽  
Friction Stir ◽  
Surface Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

Engineered materials with high hardness, great wear tolerance, high high-temperature power, and a low thermal expansion coefficient are aluminum-based composites. These materials are widely used in the automotive and aerospace industries. Friction stir processing (FSP) method used to prepare SiC reinforced aluminium alloy surface composite. Material removal rate (MRR) and surface roughness (SR) are measured with the impact of pulse on time, discharge current, and pulse off time (add one or two outcomes remark at SR and MRR optimal condition) is examined. For each of the three machining parameters, L9 orthogonal arrays (OA) of three levels were used in conducting the experiments. The validity of the Aluminum Surface Composite experiment programme is determined using MINITAB.

scholarly journals Surface Roughness Prediction for Steel 304 In Edm Using Response Graph Modeling

2018 ◽  
Vol 14 (4) ◽  
pp. 115-124 ◽  
Author(s):  
Shukry H. Aghdeab ◽  
Nareen Hafidh Obaeed ◽  
Marwa Qasim Ibraheem
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Applied Current ◽  
Graph Modeling ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Electrical Discharge Machining (EDM) is a non-traditional cutting technique for metals removing which is relied upon the basic fact that negligible tool force is produced during the machining process. Also, electrical discharge machining is used in manufacturing very hard materials that are electrically conductive. Regarding the electrical discharge machining procedure, the most significant factor of the cutting parameter is the surface roughness (Ra). Conventional try and error method is time consuming as well as high cost. The purpose of the present research is to develop a mathematical model using response graph modeling (RGM). The impact of various parameters such as (current, pulsation on time and pulsation off time) are studied on the surface roughness in the present research. 27 samples were run by using CNC-EDM machine which used for cutting steel 304 with dielectric solution of gas oil by supplied DC current values (10, 20, and 30A). Voltage of (140V) uses to cut 1.7mm thickness of the steel and use the copper electrode. The result from this work is useful to be implemented in industry to reduce the time and cost of Ra prediction. It is observed from response table and response graph that the applied current and pulse on time have the most influence parameters of surface roughness while pulse off time has less influence parameter on it. The supreme and least surface roughness, which is achieved from all the 27 experiments is (4.02 and 2.12µm), respectively. The qualitative assessment reveals that the surface roughness increases as the applied current and pulse on time increases

scholarly journals Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (3A) ◽  
pp. 319-324
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that the model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected by HAZ with 67.219% contribution.

Regression and Statistical Analysis of Process Parameters on Heat Affected Zone in Electrical Discharge Machining of Tool Steel

2020 ◽  
Vol 38 (2A) ◽  
pp. 226-231
Author(s):  
Saad K. Shather ◽  
Shukry H. Aghdeab ◽  
Waqass S. Khudier
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Workpiece Material ◽  
Input Variables ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected on HAZ with 67.219% contribution.

scholarly journals Dynamics of Perception Distortions of Human Body Physical Dimensions in Virtual Reality

2021 ◽  
Vol 18 (1) ◽  
pp. 254-270
Author(s):  
Andrey V. Varlamov ◽  
Natalya V. Yakovleva
Keyword(s):  
Virtual Reality ◽  
Human Body ◽  
Psychological Impact ◽  
Body Parts ◽  
Preliminary Measurement ◽  
Body Dimensions ◽  
Final Measurement ◽  
The Stability ◽  
High Degree ◽  
The Impact

Controlling characters in a virtual reality (VR) environment can lead to the interiorization of their body dimensions by the recipients. The possible preservation of these distortions in their psyche will indicate a high degree of psychological impact of a VR on a person and the potential danger of developing depersonalization of the recipients and their dependence on such stimulation. The study of the stability of these distortions is necessary in the context of ensuring the safety of the impact of VR environments on the human psyche. The main focus of the study is on the perception distortions of human body dimensions, as they are sensed by people immersed in a VR environment, and their dynamics depending on the number of immersions. The impact of the virtual reality environment was simulated using the Freedom Locomotion VR application. One virtual reality immersion session took 15 minutes. To obtain psychometric indicators of the subjects perception of their own body dimensions, the technique Measurements according to M. Feldenkrais was used. All the participants (N = 45, three experimental groups) underwent a mandatory preliminary measurement using this technique (several hours before exposure) and a final measurement (one day after the last exposure). At the same time, the results of preliminary measurements were taken as indicators of the subjects habitual perception of their own body dimensions and were considered in each data processing as a comparison group. Free movement in a VR environment leads to distortions in the subjects perception of their own body dimensions. In all the experimental groups, there was a tendency to exaggerate body dimensions immediately after immersions, which indicates the qualitative similarity of these distortions. The effect of repetitive immersion in a VR environment on the perception of body dimensions is that it increases awareness in perceiving body parts that are least active at the time of immersion. Controlling an anthropomorphic character in a VR leads to an increase in the subjective significance of the recipients own body perception and an increased concentration of attention on the parameters least involved in immersion. The results of the study show that an increased level of awareness in perceiving their own bodies is characteristic of the subjects who have experience of repetitive immersions in a VR environment in the guise of an anthropomorphic character. Controlling a bodily projection in a VR headset does not cause its long-term interiorization, but has a positive effect on the formation of personal corporeality.

Influence of Process Parameters on Material Removal Rate in Electrical Discharge Machining Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 91-95
Author(s):  
Tran Thi Hong ◽  
Nguyen Hong Linh ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Vu Thi Lien ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Work Piece ◽  
Influence Of Process Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

This paper aims to find the impact of Electric Discharge Machining (EDM) factors on material removal rate (MRR) for 90CrSi alloy steel. Five three-level factors including pulse on time (Ton), pulse off time (Toff), pulse current (IP), server voltage (SV), and diameter of work-piece (dw) are investigated to explore their contribution on MRR by using Taguchi method in twenty-seven experiments based on an orthogonal array L27 (35). The findings realize that MRR is the most affected by the pulse current while the effect of the dw is the smallest. Based on ANOVA analysis, an optimal model of MRR has been developed and verified by comparing with the experiment result. The applicability of this proposed method can be used for further studies in EDM process.

Evaluating Influences of Input Parameters on Surface Roughness in Sinking EDM Cylindrical Shaped Parts

2021 ◽  
Vol 1018 ◽  
pp. 85-90
Author(s):  
Tran Thi Hong ◽  
Nguyen Anh Tuan ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Work Piece ◽  
Enabling Factors ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time ◽  
Optimum Input

The input parameters in the process of sinking Electrical Discharge Machining (EDM) are the essential enabling factors that need to be determined. In the present work, the influences of the EDM input parameters containing pulse on time (Ton), pulse off time (Toff), discharge current (IP), Server voltage (SV), work-piece diameter (dw) on the surface roughness (SR) in sinking EDM cylindrical shaped part of 9CrSi material were investigated. Taguchi technique and analysis of variance (ANOVA) have been used to identify the weight of EDM factors on SR. The results show that the impact level of Ton, Toff, IP, SP, and dw are 65.55%, 8.66%, 19.17%, 3.14%, and 0.76%, respectively. By analyzing the experimental results, optimum input parameters with the Ton of 6 ms, Toff of 30 ms, IP of 9A, SP of 3V, and dw of 10mm have been determined, that allow getting the best surface roughness.

Parametric optimization in die-sinking EDM of Nimonic 90 alloy using Taguchi-based GRA approach

2020 ◽  
Vol 18 (1) ◽  
pp. 146-156
Author(s):  
Sahil Sharma ◽  
Umesh Kumar Vates ◽  
Amit Bansal
Keyword(s):  
Electric Discharge ◽  
Optimization Technique ◽  
Electrode Wear ◽  
Content Type ◽  
Response Characteristics ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact ◽  
Off Time

Purpose In the current exploration, the machining of a Nimonic 90 superalloy material was carried out in a die-sinking electric discharge machine. Experimentation was performed to investigate the impact of three input machining factors – current (I), pulse on time (Ton) and pulse off time (Toff) – on various response characteristics such as material removal rate (MRR), surface roughness (Ra) and electrode wear rate (EWR). Design/methodology/approach A Taguchi L9 design and ANOVA were used to assess machine response characteristics. The study also involved a grey relational analysis (GRA) multi-objective technique of optimization. Findings For single-objective performance, the most appropriate machining factors for achieving the best performance were attained as: MRR (I = 20 A, Ton = 200 µs and Toff = 45 µs), Ra (I = 14 A, Ton = 100 µs and Toff = 25 µs) and EWR (I = 17 A, Ton = 150 µs and Toff = 45 µs). The proposed grey relational approach provided the optimal settings (i.e. 14 A I, 100 µs Ton and 25 µs Toff) for the variables used to calculate the predicted and experimental results. Also, a confirmation test indicated that the final experimental grey relational grade value was enhanced when the experimentation was performed at optimal setting. Originality/value To the best of the authors’ knowledge, the present work is the first to examine the proposed machining variables (i.e. current, pulse on time and pulse off time) in relation to the optimization technique of GRA for a Nimonic 90 alloy using a die-sinking electric discharge machining method.

Investigation of the Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloy

2012 ◽  
Vol 472-475 ◽  
pp. 78-81 ◽  
Author(s):  
Mohinder Pal Garg ◽  
Ajai Jain ◽  
Gian Bhushan
Keyword(s):  
Surface Roughness ◽  
Water Pressure ◽  
Peak Voltage ◽  
Peak Current ◽  
Wire Breakage ◽  
Pulse Peak ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the Wire Electric Discharge Machining of Titanium alloy 6-2-4-2.Eight process parameters namely pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed, wire tension, water pressure, pulse peak voltage and servo feed are varied to study their effect on surface roughness and wire breakage. The experiments are conducted using one-factor-at-a-time approach. Moreover, a few random experiments are also carried to study the phenomenon of wire breakage precisely. The study revealed that surface roughness is directly affected by the pulse-on time, pulse-off time, peak- current, spark gap set voltage and wire tension. Wire feed, Water pressure and pulse peak voltage have negligible effect on the surface roughness. Moreover, wire breakage is predominantly dictated by all the parameters except peak current and pulse peak voltage. An optimum range of input parameters has been bracketed as the final outcome for cutting in terms of surface roughness and to minimize the wire breakage frequency.

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