scholarly journals Electrical Discharge Machining with SiC Powder-Mixed Dielectric: An Effective Application in the Machining Process of Hardened 90CrSi Steel

Machines ◽  
2020 ◽  
Vol 8 (3) ◽  
pp. 36 ◽  
Author(s):  
Thi-Hong Tran ◽  
Manh-Cuong Nguyen ◽  
Anh-Tung Luu ◽  
The-Vinh Do ◽  
Thu-Quy Le ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

As a successful solution applied to electrical discharge machining (EDM), powder-mixed electrical discharge machining (PMEDM) has been proposed as an upgrade of the EDM process. The optimization of the process parameters of PMEDM is essential and pressing. In this study, Taguchi methods and analysis of variance (ANOVA) were used to find the main parameters affecting surface roughness in the EDM process with SiC powder-mixed-dielectric of hardened 90CrSi steel. The PMEDM parameters selected were the powder concentration, the pulse-on-time, the pulse-off-time, the pulse current, and the server voltage. It was found that SiC powder exhibits positive effects on reducing surface roughness. The roughness obtained with the optimum powder concentration of 4 g/L was reduced by 30.02% compared to that when processed by conventional EDM. Furthermore, the pulse-off-time was found to be the most influential factor that gave an important effect on surface roughness followed by the powder concentration. The EDM condition including a powder concentration of 4 g/L, a pulse-on-time of 6 µs, a pulse-off-time of 21 µs, a pulse current of 8 A, and a server voltage of 4 V resulted in the best surface roughness.

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

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

Effect of Electrical Discharge Machining on Surface Roughness of Cylindrical Shaped Parts

2020 ◽  
Vol 853 ◽  
pp. 13-17
Author(s):  
Le Hong Ky ◽  
Thi Hong Tran ◽  
Nguyen Van Cuong ◽  
Tran Thanh Hoang ◽  
Do Thi Tam ◽  
...  
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Optimum Input

This paper introduces an experimental study on the influence of electrical discharge machining (EDM) cylindrical shaped parts made of 90CrSi tool steel. In this work, some experiments were designed and analysed based on Taguchi method. Also, four input parameters including the pulse on time, the pulse off time, the current, and the server voltage were investigated. The influence of these parameters on the surface roughness were estimated by analysing variance. In addition, the optimum input parameters were found for getting the minimum surface roughness.

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

2021 ◽  
pp. 095440892110607
Author(s):  
Sadananda Chakraborty ◽  
Souren Mitra ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Powder Concentration ◽  
Pulse Off Time ◽  
Off Time

Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

Influence of Some Factors on Surface Roughness Parameters at Electrical Discharge Machining

2014 ◽  
Vol 657 ◽  
pp. 291-295 ◽  
Author(s):  
Vasile Ciubotariu ◽  
Adrian Câcu ◽  
Ioana Andreea Rotundu ◽  
Marius Marian Cucoş ◽  
Margareta Coteaţă
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Operating Conditions ◽  
Machining Process ◽  
Roughness Parameters ◽  
Power Functions ◽  
Surface Roughness Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

There are various electrical discharge machining techniques and experimental researches could be necessary in order to establish the operating conditions for an optimal machining process. Some theoretical considerations concerning the process of generating the surface asperities as a consequence of the electrical discharge machining process were elaborated. Experimental method was applied in order to evaluate influence exerted by some input factors (pulse on time, pulse off time, average intensity of electric current) on certain surface roughness parameters (Ra, Rz, Ry and Rq). One developed an experimental research by using a copper tool electrode and a workpiece made of high speed steel, in accordance with the requirements specific to a complete factorial experiment with three independent variables at three levels. A ram electrical discharge machine was used as machining equipment. One measured the surface roughness parameters specific to the machined surfaces. Empirical mathematical models of type power functions were established by using the method of least squares.

Effect of impregnated powder materials on surface integrity aspects of Inconel 625 during electrical discharge machining

2016 ◽  
Vol 232 (7) ◽  
pp. 1259-1272 ◽  
Author(s):  
Gangadharudu Talla ◽  
Soumya Gangopadhyay ◽  
CK Biswas
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Integrity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Inconel 625 ◽  
Powder Materials ◽  
Powder Concentration ◽  
Pulse On Time

In recent times, nickel-based super alloys are widely utilized in aviation, processing, and marine industries owing to their supreme ability to retain the mechanical properties at elevated temperature in combination with remarkable resistance to corrosion. Some of the properties of these alloys such as low thermal conductivity, strain hardening tendency, chemical affinity, and presence of hard and abrasives phases in the microstructure render these materials very difficult-to-cut using conventional machining processes. In this work, an experimental setup was developed and integrated with the existing electrical discharge machining system for carrying out powder-mixed electrical discharge machining process for Inconel 625. The experiments were planned and conducted by varying five different variables, that is, powder concentration, peak current, pulse-on time, duty cycle, and gap voltage based on the central composite design of response surface methodology. Effects of these parameters along with powder concentration were investigated on various surface integrity aspects including surface morphology, surface roughness, surface microhardness, change in the composition of the machined surface, and residual stress. Results clearly indicated that addition of powder to dielectric has significantly improved surface integrity compared to pure dielectric. Among the powders used, silicon has resulted in highest microhardness, that is, almost 14% more than graphite. Lowest surface roughness (approximately 50% less than pure kerosene) and least residual stress were obtained using silicon powder (approximately 8% less than graphite-mixed dielectric). Relative content of nickel was reduced at the expense of Nb and Mo after addition of powders like aluminum and graphite in dielectric during electrical discharge machining.

Optimization of Wedm Parameters for Surface Roughness on Hybrid Mmcs

2014 ◽  
Vol 23 (3) ◽  
pp. 096369351402300
Author(s):  
D. Satishkumar ◽  
M. Kanthababu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Matrix Composites ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Unconventional Machining ◽  
Central Composite ◽  
Wire Feed

Metals or alloys when reinforced with more than one reinforcement materials are generally considered as hybrid metal matrix composites (MMCs). The superior properties of the hybrid MMCs deter its wide applications due to the difficulty in machining. Wire electrical discharge machining (WEDM) is an effective unconventional machining process which can be used to machine difficult to machine materials. This work is aimed towards optimizing the WEDM parameters to achieve better surface roughness ( Ra) during machining of stir cast unreinforced A17075 alloy and A17075/B4C/Al2O3 based hybrid MMCS. The experiments were carried out as per central composite design of response surface methodology (RSM). It is observed that all the process parameters such as pulse-on time ( TON), pulse-off time ( TOFF), wire feed (F), gap voltage (V) considered in this work were significant.

Research on Tool Wear Rate of Powder Mixed near Dry Electrical Discharge Machining

2013 ◽  
Vol 652-654 ◽  
pp. 2222-2227 ◽  
Author(s):  
Xue Bai ◽  
Qin He Zhang ◽  
Ting Yi Yang ◽  
Jian Hua Zhang ◽  
Jing Tan
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Tool Wear Rate ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Dry Electrical Discharge Machining

Powder mixed near dry electrical discharge machining (PMND-EDM) is one of the novel EDM processes, which uses gas-liquid-powder mixture as the dielectric medium. The tool wear rate (TWR) in PMND-EDM is researched based on single factor experiments. Effects of process parameters, such as peak current, pulse on time, pulse off time, flow rate, powder concentration, tool rotational speed and air pressure, on TWR are found out. TWR increases with the increase of peak current. TWR decreases with increasing of pulse on time. TWR increases firstly and then decreases while pulse off time increases. Increase of flow rate results in the increase of TWR. With the increase of powder concentration, TWR increases firstly and then decreases. Existence of tool rotation facilities decrease of TWR, however, further increase of rotational speed leads to increase of TWR. Increase of air pressure leads to lower TWR.

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