Influence of Adaptive Gap Control Mechanism and Tool Electrodes on Machining Titanium (Ti-6Al-4V) Alloy in EDM Process

Titanium alloy is widely used for orthodontic technology and easily machined using the EDM process. In the EDM process, the workpiece and tool electrode must be separated by a continuous air gap during the machining operation to generate discharge energy in this method. In the present study, an endeavor was made to analyze the effects of a servo feed air gap control and tool electrode in the EDM process. The developed mechanical setup consists of a linear action movement with zero backlash along the X-axis, which can be controlled up to 0.03 mm. It was observed that the suggested air gap control scheme can enhance the servo feed mechanism on a machining titanium alloy. A tungsten carbide electrode can enhance the surface measures owing to its ability to produce tiny craters with uniform distribution. Since it produces a little crater and has a higher melting point, a tungsten carbide electrode can create lesser surface roughness than a copper tool and brass tool electrode.

Download Full-text

Optimization of Surface Roughness Parameters by Different Multi-Response Optimization Techniques During Electro-Discharge Machining of Titanium Alloy

Non-Conventional Machining in Modern Manufacturing Systems - Advances in Mechatronics and Mechanical Engineering ◽

10.4018/978-1-5225-6161-3.ch004 ◽

2019 ◽

pp. 82-108 ◽

Cited By ~ 2

Author(s):

Anshuman Kumar Sahu ◽

Siba Sankar Mahapatra

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Discharge Current ◽

Desirability Function ◽

Optimization Techniques ◽

Work Piece ◽

Tool Electrode ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Edm Process

In this chapter, the EDM process is performed by taking titanium alloy as work piece and AlSiMg prepared by selective laser sintering (SLS) process as tool electrode along with copper and graphite. The EDM is performed by varying different process parameters like voltage (V), discharge current (Ip), duty cycle (τ), and pulse-on-time (Ton). The surface roughness parameters like Ra, Rt, and Rz are measured by the use of surface roughness measurement machine. To reduce the number of experiments, design of experiment (DOE) approach like Taguchi's L27 orthogonal array has been used. The surface properties of the EDM specimen are optimized by desirability function approach, TOPSIS and VIKOR method, and the best parametric setting is reported for the EDM process. All the optimization techniques convergence to the same optimal parametric setting. The type of tool is the most significant parameter followed by discharge current and voltage. Better surface finish of EDM specimen is produced with lower level of parametric setting along with the use of AlSiMg RP electrode during EDM.

Download Full-text

DSP based implementation of piecewise linear control scheme for wide air-gap control of an electromagnetic levitation system

IECON 2015 - 41st Annual Conference of the IEEE Industrial Electronics Society ◽

10.1109/iecon.2015.7392267 ◽

2015 ◽

Author(s):

Mrinal Kanti Sarkar ◽

Subrata Banerjee

Keyword(s):

Piecewise Linear ◽

Electromagnetic Levitation ◽

Air Gap ◽

Linear Control ◽

Control Scheme ◽

Levitation System ◽

Gap Control

Download Full-text

Fabrication of Micro Components to Silicon Wafer Using EDM Process

Materials Science Forum ◽

10.4028/www.scientific.net/msf.505-507.217 ◽

2006 ◽

Vol 505-507 ◽

pp. 217-222 ◽

Cited By ~ 2

Author(s):

Feng Tsai Weng ◽

Chen Siang Hsu ◽

Wen Feng Lin

Keyword(s):

Tungsten Carbide ◽

Silicon Wafer ◽

Electrode Array ◽

Copper Electrode ◽

Silicon Wafers ◽

Tool Electrode ◽

Micro Holes ◽

Micro Hole ◽

Fine Tungsten ◽

Edm Process

In this paper, the machining possibilities of silicon wafers by the EDM process are described. Micro components of silicon wafer were processed by EDM process. A fine tungsten carbide rod was machined as tool electrode for EDM process. Performance was investigated utilizing serious experiments. Micro hole was process with the fine electrode using EDM drilling. Micro slots were also processed on the surface of a silicon plate by a copper section electrode. The surface roughness of the silicon wafers in the EDM process was investigated. Array-micro-hole was machined by a tungsten carbide multi-electrode. Array micro holes on the coaxial circle were processed by a graphite-copper electrode of Dia.0.45mm. Batch production technology for economical EDM machining of micro holes were proposed.

Download Full-text

Finite Element Modeling of Discharge Zone in Micro-EDM Process

Volume 3: Design, Materials and Manufacturing, Parts A, B, and C ◽

10.1115/imece2012-86112 ◽

2012 ◽

Author(s):

Jose Mathew ◽

Deepak G. Dilip ◽

Mathew J. Joseph ◽

Basil Kuriachen

Keyword(s):

Finite Element ◽

Titanium Alloy ◽

Removal Rate ◽

Discharge Zone ◽

Dielectric Fluid ◽

Work Piece ◽

Uniform Mesh ◽

Tool Electrode ◽

Micro Edm ◽

Edm Process

Micro-EDM (μ-EDM) is a derived form of EDM process especially evolved to perform micro-machining. The μ-EDM process is based on the thermoelectric energy created between a work piece and an electrode submerged in a dielectric fluid. When the work piece and the electrode are separated by a specific small gap, a pulsed discharge occurs which removes material from the work piece through melting and evaporation. A thermo-electrical approach to model the temperature variation in the discharge gap using finite element method has been done so as to predict the temperature distribution in the discharge channel and find out the maximum temperatures acting on the work piece as well as the tool electrode and the subsequent material removal rate on the work piece. The temperature generated on the surface of the work piece depends upon the various properties of the conductor; as a result it varies depending on the conductor. An axi-symmetric two-dimensional model was used for modeling the region between the two electrodes. Tungsten and titanium alloy were the materials used for cathode and anode, respectively. A 60μm by 60μm region was taken for modeling the process. An uniform mesh of equal dimensions was made to carry out the modeling. The finite element results were compared with the results obtained by conducting experiments on titanium alloy using single spark generator device under the same discharge conditions that were given as input for the mathematical model. The MRR obtained agrees very well with the predicted MRR thus validating the model.

Download Full-text

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

Engineering and Technology Journal ◽

10.30684/etj.v38i9a.552 ◽

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.

Download Full-text

Multi-Response Optimization of Wire-EDM Process Parameters of Titanium Alloy Using Taguchi Method and Grey Relational Analysis

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.772.245 ◽

2015 ◽

Vol 772 ◽

pp. 245-249

Author(s):

A. Ramamurthy ◽

R. Sivaramakrishnan ◽

S. Venugopal ◽

T. Muthuramalingam

Keyword(s):

Titanium Alloy ◽

Process Parameters ◽

Grey Relational Analysis ◽

Wire Edm ◽

Relational Analysis ◽

Response Optimization ◽

Grey Relational ◽

Pulse On Time ◽

Pulse Off Time ◽

Edm Process

It is very important and complexity to find the optimum values of wire EDM process parameters and contribution of each parameter to attain the better performance characteristics. In this study, an attempt has been made to optimize those parameters while machining the titanium alloy. Since the process involves more one than one response parameter, it is essential to carry out the multi-response optimization methodology .The experiments have been conducted with different levels of input factors such as pulse on time,pulse off time and wire tension based on Taguchi L9 orthogonal table.Wire EDM optimal process parameter has been identified using grey relational analysis and significant parameter has been determined by analysis of variance. Experimental results have indicated that the multi-response characteristic such as material removal rate and surface roughness can be improved effectively through grey relational analysis.

Download Full-text

A Hierarchical Access Control Scheme Based on Lagrange Interpolation and ELGamal Algorithm with Numerical Experiments

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.385-386.1705 ◽

2013 ◽

Vol 385-386 ◽

pp. 1705-1707

Author(s):

Tzer Long Chen ◽

Yu Fang Chung ◽

Jian Mao Hong ◽

Jeng Hong Jhong ◽

Chin Sheng Chen ◽

...

Keyword(s):

Access Control ◽

Lagrange Interpolation ◽

Control Mechanism ◽

Key Generation ◽

Electronic Documents ◽

Control Scheme ◽

Video Systems ◽

Efficient Scheme ◽

On Line ◽

Access Control Mechanism

It is important to notice that the access control mechanism has been widely applied in various areas, such as on-line video systems, wireless network, and electronic documents. We propose an access control mechanism which is constructed based on two mathematical fundamentals: Lagrange interpolation and ElGamal algorithm. We conduct performance analysis to compare the efficiency of our proposed scheme with that of several related published schemes in both key generation phase and key derivation phase. Our new scheme is proven to be more efficient. It is shown, as expected, a more efficient scheme provides relatively less security and a more secure scheme is relatively less efficient for private keys of the same size.

Download Full-text