scholarly journals Parametric Optimization of EDM Process for Hybrid Metal Matrix using GRA Method

2019 ◽  
Vol 8 (3) ◽  
pp. 5844-5848
Keyword(s):  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Matrix Composites ◽  
Hybrid Metal Matrix Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Grey Relation ◽  
Off Time ◽  
Edm Process

Metal matrix composites (MMC’s) have evolved an extreme attention in current era for their superior applications in aerospace, defence and automobile industries. Metal matrix composites are found as current materials, possessing the characteristics of light in weight, greater wear resistance & superior specific strength. Due to presents of high hardened reinforcement strength, composite materials are very difficult to do machining by traditional techniques. Therefore unconventional machining like Electrical Discharge Machining becomes feasible method to these kinds of composite materials. EDM process does not require any mechanical energy because there is no direct contact between tool and workpiece. So there no influence of superior material properties like hardness, strength, toughness etc in machining hybrid metal matrix composite. In the present paper , an analysis is carried out to evaluate the influence of input parameters such as peak current (I), tool lift (TL), pulse off time (T off) and pulse on time (Ton) on the machining of 90%-Al(6061)-3 weight % silicon carbide (SiC)-7 weight % boron carbide (B4C) hybrid metal matrix composite through electrical discharge machining. The individual parameters were analyzed with an objective to minimize tool wear ratio (TWR) and to maximize the material removal rate (MRR). The grey relation grade (GRG) for Electric discharge machining is obtained by using taghuchi based grey relation analysis (GRA) method with multiple response parameters like MRR and TWR. The ANOVA based GRA method is employed to find the significance of process parameters like Peak Current, Pulse on time, and Pulse off time and Tool lif

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.

Multi-response Optimization in Wire Electrical Discharge Machining (WEDM) of Al6061/SiCp Composite Using Hybrid Approach

2015 ◽  
Vol 15 (4) ◽  
pp. 327-338 ◽  
Author(s):  
K. Anand Babu ◽  
P. Venkataramaiah
Keyword(s):  
Silicon Carbide ◽  
Process Parameters ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

AbstractIn recent days, the silicon carbide particulate reinforced aluminium metal matrix composites are most promising material in various engineering applications due to their strength to weight ratio, wear resistance and thermal resistance over the non-reinforced alloys. However, these materials are very difficult to cut by conventional machining methods due to the presence of silicon carbide particles. To overcome this limitation, the wire electrical discharge machining (WEDM) is employed to machine these composites. The aim of this study is to optimize the process parameters in wire electrical discharge machining (WEDM) of Al6061/SiCp composite using AHP-TOPSIS method. Al 6061/2% SiCp/3 µm particulate metal matrix composite is fabricated by using stir casting method and the uniformity of particle distribution was analyzed by SEM. Taguchi L18 orthogonal array is designed by considering various process parameters viz. Wire Type (WT), Pulse ON Time (T ON), Pulse OFF Time (T OFF), Wire Feed rate (WF) and Sensitivity (S) for conducting WEDM experiments. The obtained experimental results were analyzed and the results revealed that Sensitivity (S) is the prevailing factor on the response characteristics of WEDM followed by pulse ON time (T ON), wire feed rate (WF), Wire Type (WT) and pulse OFF time (T OFF).

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

Experimental Evaluation on Corner Accuracy in WEDM for Aluminium 6061 Alloy

2021 ◽  
pp. 96-113
Author(s):  
Debal Pramanik ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Thermal Process ◽  
Electrical Discharge Machining ◽  
Sharp Corner ◽  
Proposed Model ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

An important electro-thermal process known as wire electrical discharge machining (WEDM) is applied for machining of conductive materials to generate most precisely. All cutting inaccuracies of WEDM arise out of the major cause of wire bending. At the time of cutting a sharp corner or cut profile, bending of the wire leads to a geometrical error on the workpiece. Though this type of error may be of a few hundred microns, it is not suitable for micro applications. In this research study, an experimental investigation based on response surface methodology (RSM) has been done on wire EDM of Aluminium 6061 t6 alloy. This chapter studies the outcome of input process variables (i.e., wire feed rate, pulse on time, pulse off time, and gap voltage) on machining output responses (i.e., corner inaccuracy) extensively. Experimental validation of the proposed model shows that corner inaccuracy value may be reduced by modification of input parameters.

Relationship between the Fine Discharge Parameters and Craters EDMed of the NAK80 Steel

2010 ◽  
Vol 426-427 ◽  
pp. 85-88
Author(s):  
Hong Jun Wang ◽  
Dun Wen Zuo ◽  
X.M. Wu ◽  
M. Wang
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Discharge Voltage ◽  
Optimization Scheme ◽  
Crater Diameter ◽  
Open Discharge ◽  
Discharge Parameters ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

The crater diameter and depth of the surface machined by electrical discharge machining (EDM) were used to evaluate indexes for EDMed surface. The influence of discharge parameters selected on the crater diameter and depth in mirror-like surface EDM process was investigated, and the optimization scheme was obtained. An L16 (44×23) Taguchi standard orthogonal array was chosen for the design of experiments. Experimental results indicate that peak current and open discharge voltage have more influence on the crater diameter and depth in comparison with pulse off-time and pulse duration. Also the results confirm that the crater depth is about 10 to 20 percent of its diameter while the near-mirror EDM conducted in the NAK80 steel with fine discharge parameters.

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.

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. 

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.

Sign in / Sign up

Export Citation Format

Share Document