Einsatz eines naturanalogen Algorithmus/Application of a natural analogue algorithm – Reproducible optimization of electrical-discharge drilling

2020 ◽  
Vol 110 (07-08) ◽  
pp. 467-470
Author(s):  
Eckart Uhlmann ◽  
Mitchel Polte ◽  
Jan Streckenbach ◽  
Mirsad Osmanovic ◽  
Julian Börnstein
Keyword(s):  
Industrial Application ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Optimization Method ◽  
Hardened Steel ◽  
Evolution Strategy ◽  
Natural Analogue ◽  
Electrical Discharge Drilling ◽  
Materials Used

Dieser Beitrag stellt die Ergebnisse zur Untersuchung der Reproduzierbarkeit des Optimierungsverfahrens Evolutionsstrategie (ES) am Beispiel des funkenerosiven Bohrens vor. Dazu wurden zwei ES-Typen untersucht. Als Elektrodenwerkstoffe kamen Messing für das Werkzeug und für das Werkstück gehärteter Stahl zum Einsatz. Im Ergebnis konnte die Erosionsdauer reproduzierbar um 37 % verringert werden. Dieser Nachweis bildet die Grundlage für den industriellen Einsatz der Evolutionsstrategie beim funkenerosiven Bohren.   This article describes the results of the investigation on the reproducibility of the optimization method of evolution strategy (ES), exemplified by electrical-discharge drilling. Two types of ES were examined. The electrode materials used were brass for the tool and hardened steel for the workpiece. The erosion duration could be reduced by 37 % in a reproduceable manner. This verification is the basis for the industrial application of the ES for the optimization of electrical discharge machining.

A Survey on Electrode Materials for Electrical Discharge Machining

2011 ◽  
Vol 697-698 ◽  
pp. 495-499 ◽  
Author(s):  
Li Zhang ◽  
Li Hua Dong ◽  
D.S. Wang ◽  
C.H. Fan ◽  
Y. Zhou
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Industrial Applications ◽  
High Wear Resistance ◽  
Wear Loss ◽  
Melting Points ◽  
Edm Electrodes ◽  
Materials Used ◽  
Shape Loss

This work screens electrode materials used in EDM and proposes some potential electrodes for future industrial applications. Traditional graphite, W, and Mo EDM electrodes have low TWR due to their high melting points; while, Zn, brass, and Cu often experience too much tool wear. As to some newly developed alloy and composite materials, their machining performances depend on not only their melting points but also their microstructures. Cu-W alloy has high wear resistance but it is susceptible to shape loss due to its internal porosity. By contrast, Cu-graphite, Cu-ZrB2 and Cu-TiB2 composites show good capabilities of removing material with little wear loss and therefore could be promising for future usages.

Analysis of Electrical Discharge Machining Using Water as Dielectric and Diverse Electrode Materials

2008 ◽  
Author(s):  
Hugo Medellin ◽  
Aaro´n Flores ◽  
Jorge Morales ◽  
Alonso de la Garza
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Low Carbon Steel ◽  
Electrode Wear ◽  
Low Carbon ◽  
Source Voltage ◽  
Materials Used ◽  
Edm Process

This paper presents an experimental investigation carried out to study the performance of electrical discharge machining (EDM) using water as dielectric. This experimentation was performed using different types of water as dielectric, several electrode materials and two different workpiece materials. The electrode materials used in the experimentation were bronze, brass, copper, aluminium and steel; and the workpiece materials used were ASTM A36 mild (low-carbon) steel and D-2 tool steel. A new desktop size EDM machine to perform the experiments was designed and is presented in this paper. After performing the experimentation, the results have shown that the best EDM performance is achieved with brass and bronze electrodes using a mixture of 75% tap and 25% deionised water as dielectric. The results also indicate that the material removal rate and the electrode wear are proportional to the source voltage used in the EDM process. Finally, a forming die with a complex shape used in a jewellery industry, was manufactured using the EDM system presented in this paper.

A Multiobjective Genetic-Algorithm-Based Optimization of Micro-Electrical Discharge Drilling

2021 ◽  
pp. 676-698
Author(s):  
Deepak Rajendra Unune ◽  
Amit Aherwar
Keyword(s):  
Genetic Algorithm ◽  
Process Parameters ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining ◽  
Electrical Discharge Drilling ◽  
Machining Rate

Inconel 718 superalloy finds wide range of applications in various industries due to its superior mechanical properties including high strength, high hardness, resistance to corrosion, etc. Though poor machinability especially in micro-domain by conventional machining processes makes it one of the “difficult-to-cut” material. The micro-electrical discharge machining (µ-EDM) is appropriate process for machining any conductive material, although selection of machining parameters for higher machining rate and accuracy is difficult task. The present study attempts to optimize parameters in micro-electrical discharge drilling (µ-EDD) of Inconel 718. The material removal rate, electrode wear ratio, overcut, and taper angle have been selected as performance measures while gap voltage, capacitance, electrode rotational speed, and feed rate have been selected as process parameters. The optimum setting of process parameters has been obtained using Genetic Algorithm based multi-objective optimization and verified experimentally.

Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

2019 ◽  
Vol 969 ◽  
pp. 644-649
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Work Piece ◽  
Tool Electrode ◽  
Affecting Factors ◽  
Inconel 718 Alloy ◽  
Electrical Discharge Drilling ◽  
Pulse On Time

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

Electrode Material Effect on Electrical Discharge Machining PcBN Cutting Tool Processing

2011 ◽  
Vol 399-401 ◽  
pp. 1667-1671 ◽  
Author(s):  
Yun Hai Jia
Keyword(s):  
Surface Quality ◽  
Electric Discharge ◽  
Electrode Material ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Electric Discharge Machining ◽  
Tool Surface

The electrode material is playing the very important role in the electrical discharge machining. Two kinds of electrode materials common used in EDM are compared and analyses similarities and differences in structure and physical characteristics. Combined with PcBN tool machining tests, from the electric discharge machining efficiency, electrode wear, tool surface quality, tool surface degenerating layer, machining results are in analysis and comparison, and then different electrode materials machining technics in electrical discharge machining process are summarized. Through the cutting tool electric discharge machining experiments, we can know that the graphite electrode easy to take shape, suits in the complex edge's cutting tool electric discharge machining, under the same electric discharge machining parameter condition, its processing efficiency must be higher than the copper electrode, but the electrode loses, the cutting tool surface quality and affect layer thickness are to be worse than the copper electrode.

scholarly journals Formation and Optimization of Electrical Discharge Coatings Using Conventional Electrodes

Energies ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5691
Author(s):  
JagadeeswaraRao Maddu ◽  
Buschaiah Karrolla ◽  
Srikanth Vuppala ◽  
Riyaaz Uddien Shaik
Keyword(s):  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
Titanium Substrate ◽  
Dielectric Medium ◽  
Optimization Techniques ◽  
Functional Coatings ◽  
Discharge Machine ◽  
Angle Method

An emerging topic is electrical discharge (ED) coating with its application on complex shapes and cavities to repair components or act as functional coatings. Because it is a variant process of an electric discharge machine (EDM) with the ability to coat on electrically conductive substrates, there is a possibility that next-generation electrical discharge machining components may exploit the attachment phenomenon to enhance recast layer properties. Previously, researchers have obtained ED coating by mixing the powder in a dielectric medium and/or by using powder metallurgy electrodes. In this work, primarily, an insight in the formation of ED coating on-die sinks electrical discharge machine, using conventional electrode materials viz., bronze on titanium alloy (Ti-6Al-4V) is made. The bronze electrode on the titanium substrate obtained a crack-free copper coating of ~20 microns thickness. In order to perform the experiments, three combinations were made using five parameters: current (Amps), ton (µs), Toff (µs), duty cycle (%), and flushing pressure as constant (bar). After obtaining the coating, a combination of input parameters was selected by optimizing the output performance parameters, viz., the electrical discharge deposition rate, coating thickness, micro-cracks, and elemental coating composition. Secondarily, different optimization techniques viz., grey relational analysis, the technique for order of preferences by similarity to ideal solution, −nD angle method and information divergence method were implemented to find out the suitable combination of parameters where the latter two methods were introduced for the first time in this area of EDM optimization. A study was conducted to check whether the latter two methods are optimization techniques or multi-criteria decision-making techniques. The optimization of existing reactor types and the development of new reactors in wastewater treatment through EDC, by which energy could be saved by replacing the conventional techniques.

Effect of Wire Electrode Materials on Performance Characteristics for Wire Electrical Discharge Machining of Metal Matrix Composite Material

2020 ◽  
Author(s):  
Gurupavan Hurugalavadi Ramu ◽  
Holalu Venkatadas Ravindra ◽  
Devegowda Tadagavadi Muddegowda
Keyword(s):  
Silicon Carbide ◽  
Composite Materials ◽  
Surface Finish ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Electrode Wear ◽  
Wire Electrical Discharge Machining ◽  
Brass Wire

Abstract Composite materials are the advanced materials which are widely used in manufacturing industries. The most commonly used composite materials are metal matrix composites. Due to the presence of abrasive reinforcing particles, traditional machining of these causes severe tool wear and hence reduces the life of cutting tool. Wire electrical discharge machining (WEDM) is quite successful for machining of metal matrix composites. Wire Electrical Discharge machining is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. One of the main research fields in WEDM is related to the improvement of the process productivity by avoiding wire breakage. Wire electrodes used in WEDM are the core of the system. In this study the effect of different wire electrode materials on electrode wear and surface finish for wire electrical discharge machining of metal matrix composite material were investigated. The experiments were conducted under the following process parameters viz., pulse-on time, pulse-off time, wire feed speed and current. For the experiment the aluminium 6061 alloy with 0%, 5%, and 10% of silicon carbide (SiC) reinforcement material was used. To conduct the experiment CNC wire EDM machine with two different wires viz., molybdenum and brass wire was used. Experimental results indicate that for better surface finish of Al6061 alloy, the brass wire is more suitable. The use of brass wire as electrode material leads to significant reduction in electrode wear in machining of Al-5%SiC and Al-10%SiC composite materials compare to molybdenum wire. Increasing percentage of silicon carbide in aluminium 6061 alloy increases the variation in surface finish and electrode wear. Wire wear rate of both brass and molybdenum wire is increased with increase in percentage of silicon carbide.

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