EDM Process Parameters Optimization for Al-TiO2 Nano Composite

Titanium aluminide reinforced aluminium based metal matrix nano composite was prepared by stir casting route. Experiments were conducted with Cu electrode using L9 orthogonal array based on the Taguchi method. Discharge current (Lv), Pulse on time (Ton) and Flushing pressure (FP) are selected to calculate Metal removal rate (MRR), Tool wear rate (TWR) and Surface roughness (SR) based on Taguchi's parameter design. Moreover, the signal-to-noise ratios associated with the observed values in the experiments were determined using MINITAB software for MRR, TWR and SR. PCR – TOPSIS method is used to optimize Taguchi's multi response. Optimum parameter setting is found at Discharge current (Lv) 10 A, Pulse on time (Ton) 150 µs and Flushing pressure (FP) 1 kg/cm2.

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Parameter Design of EDM Process to Optimize Surface Roughness and Material Removal Rate Using Taguchi Method

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1028.391 ◽

2021 ◽

Vol 1028 ◽

pp. 391-396

Author(s):

Muhammad Firly Firmansyah ◽

Suwarno Suwarno ◽

Yanuar Rohmat Aji Pradana ◽

Suprayitno Suprayitno

Keyword(s):

Surface Roughness ◽

Material Removal Rate ◽

Discharge Current ◽

Material Removal ◽

Removal Rate ◽

Parameter Design ◽

Pulse On Time ◽

Pulse Off Time ◽

Off Time ◽

Edm Process

Electrical discharge machining (EDM) is a non-conventional process that is widely used for high-precision machining, complex product shapes, and high hardness materials. The EDM mechanism is based on the thermoelectric energy between the electrode and the workpiece. The EDM process has many parameters that can be adjusted, such as discharge current, voltage, pulse on time, pulse off time, electrode polarity, workpiece material, electrode material, dielectric fluid type, flushing pressure, flushing direction and flushing method. This study aims to find the parameters of the EDM process to optimize its productivity indicated by material removal rate (MRR) and its quality indicated by surface roughness of SS-316 material. The varied parameters were discharge current, pulse on time, and pulse off time with 3 levels for each parameter. Fractional orthogonal array L9 were applied for three 3-level variables. Performance fluctuation due to noise factors were simply approximated by 3 replicating measurements to estimate mean and standard deviation. Taguchi S/N ratio were adopted as robustness index for the optimum parameter design. The optimization results show that the discharge current 30A, pulse on time 100μs, and pulse off time 8μs are the optimum for MRR. As for surface roughness, the discharge current is 10A, pulse on time is 100μs, and pulse off time is 8μs. The only different of EDM parameter for optimum MRR and optimum Ra is discharge current.

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Prediction of EDM Process Parameters for AISI 1020 Steel using RSM, GRA and ANN

International Journal of Recent Technology and Engineering - 2 ◽

10.35940/ijrte.b1010.0782s319 ◽

2019 ◽

Vol 8 (2S3) ◽

pp. 51-63

Keyword(s):

Metal Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Discharge Voltage ◽

Copper Electrode ◽

Gray Relational Analysis ◽

Pulse On Time ◽

Pulse Off Time ◽

Off Time ◽

Edm Process

AISI 1020 Steel is hard while machining because of its nature of harness and brittleness. Electrical Discharge Machining (EDM) is a significant technique to machine such materials. Current research examines the pulse current effect (A), discharge voltage (B), pulse on time (C), pulse off time (D),Oil pressure (E)and spark gap(F) on Metal Removal Rate (MRR) and Surface Roughness on EDM of AISI 1020 Steel. Experiments have been carried out in a methodical type taking up nearly 54 successive trails utilizing an EDM machine and a copper electrode of 10mm diameter. Three factors, three levels, Box Bekhen through response surface methodology design was utilized to analyze the outcomes. Gray relational analysis techniques are adopted for finding parameter influencing range for MRR and SR. A multi regression mathematical model was brought up in launching the association between parameters of machining and artificial neural network techniques are used for predicting the optimized parameters.

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Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

International Journal of Automotive and Mechanical Engineering ◽

10.15282/ijame.17.3.2020.06.0610 ◽

2020 ◽

Vol 17 (3) ◽

pp. 8128-8139

Author(s):

S. Chakraborty ◽

S. Mitra ◽

D. Bose

Keyword(s):

Metal Removal ◽

Removal Rate ◽

Machining Process ◽

Process Efficiency ◽

Machining Parameters ◽

Dielectric Fluids ◽

High Emission ◽

Pulse On Time ◽

Pulse Off Time ◽

Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

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Parametric Analysis of Different Grades of Steel Materials Used in Plastic Industries through Die Sinking EDM Process

International Journal of Materials Forming and Machining Processes ◽

10.4018/ijmfmp.2016010104 ◽

2016 ◽

Vol 3 (1) ◽

pp. 45-74 ◽

Cited By ~ 2

Author(s):

Goutam Kumar Bose ◽

Pritam Pain

Keyword(s):

Removal Rate ◽

Research Work ◽

Entropy Method ◽

Control Parameters ◽

Well Design ◽

Materials Used ◽

Linear Graphs ◽

Pulse On Time ◽

Pulse Off Time ◽

Edm Process

In the present research work four different work materials viz. EN24, D2, H13, P20 which are commonly use in plastic industries are considered for machining applying EDM process. Four different control parameters such as pulse on time, pulse off time, gap current, and Spark gap are considered to study the effect on the performance of responses like material removal rate, surface roughness and overcut using a square shape copper tool with lateral flushing. A well design experimental plan is used to reduce the total number of experiment following L9 orthogonal array. Based on Taguchi methodology the significant process parameters affecting the responses are identified applying ANOVA for each material. The effect of the responses with respect to the four control parameters for the four different work materials is compared through linear graphs. A well-known Grey relational analysis is carried out where the weights are calculated using entropy method to full fill the multi criteria decision making process.

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Relevance Vector Machine Based Analyses of MRR and SR of Electrodischarge Machining Designed by Response Surface Methodology

International Journal of Manufacturing Engineering ◽

10.1155/2013/170746 ◽

2013 ◽

Vol 2013 ◽

pp. 1-9 ◽

Cited By ~ 1

Author(s):

Kanhu Charan Nayak ◽

Rajesh Kumar Tripathy ◽

Sudha Rani Panda

Keyword(s):

Response Surface Methodology ◽

Response Surface ◽

Duty Cycle ◽

Discharge Current ◽

Removal Rate ◽

Relevance Vector Machine ◽

Machining Process ◽

Machining Parameters ◽

Electrodischarge Machining ◽

Pulse On Time

Relevance vector machine is found to be one of the best predictive models in the area of pattern recognition and machine learning. The important performance parameters such as the material removal rate (MRR) and surface roughness (SR) are influenced by various machining parameters, namely, discharge current (Ip), pulse on time (Ton), and duty cycle (tau) in the electrodischarge machining process (EDM). In this communication, the MRR and SR of EN19 tool steel have been predicted using RVM model and the analysis of variance (ANOVA) results were performed by implementing response surface methodology (RSM). The number of input parameters used for the RVM model is discharge current (Ip), pulse on time (Ton), and duty cycle (tau). At the output, the corresponding model predicts both MRR and SR. The performance of the model is determined by regression test error which can be obtained by comparing both predicted MRR and SR from model and experimental data is designed using central composite design (CCD) based RSM. Our result shows that the regression error is minimized by using cubic kernel function based RVM model and the discharge current is found to be one of the most significant machining parameters for MRR and SR from ANOVA.

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Recent Advances and Perceptive Insights into Powder-Mixed Dielectric Fluid of EDM

Micromachines ◽

10.3390/mi11080754 ◽

2020 ◽

Vol 11 (8) ◽

pp. 754 ◽

Cited By ~ 2

Author(s):

Asarudheen Abdudeen ◽

Jaber E. Abu Qudeiri ◽

Ansar Kareem ◽

Thanveer Ahammed ◽

Aiman Ziout

Keyword(s):

Tool Wear ◽

Metal Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Dielectric Fluid ◽

Dielectric Fluids ◽

Advanced Machining ◽

Low Efficiency ◽

Edm Process ◽

Powder Mixed Edm

Electrical discharge machining (EDM) is an advanced machining method which removes metal by a series of recurring electrical discharges between an electrode and a conductive workpiece, submerged in a dielectric fluid. Even though EDM techniques are widely used to cut hard materials, low efficiency and high tool wear remain remarkable challenges in this process. Various studies, such as mixing different powders to dielectric fluids, are progressing to improve their efficiency. This paper reviews advances in the powder-mixed EDM process. Furthermore, studies about various powders used for the process and its comparison are carried out. This review looks at the objectives of achieving a more efficient metal removal rate, reduction in tool wear, and improved surface quality of the powder-mixed EDM process. Moreover, this paper helps researchers select suitable powders which are exhibiting better results and identifying different aspects of powder-mixed dielectric fluid of EDM.

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Effect of Process Parameters in Electric Discharge Machining of Ti-6Al–4V Alloy by Three Different Tool Electrode Materials

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.488-489.876 ◽

2012 ◽

Vol 488-489 ◽

pp. 876-880 ◽

Cited By ~ 3

Author(s):

Manoj Kumar Kuttuboina ◽

A. Uthirapathi ◽

Singaravelu D. Lenin

Keyword(s):

Process Parameters ◽

Electrode Material ◽

Electrode Materials ◽

Metal Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Copper Electrode ◽

Tool Electrode ◽

Good Surface ◽

Pulse On Time

The effect of process parameters namely peak current, pulse on time and flushing pressure on electrical discharge machining (EDM) of titanium alloy (Ti–6Al–4V) were investigated by using three different tool electrode materials namely copper, brass, and aluminium. Kerosene is used as dielectric. The process parameters for machining Ti6Al4V are varied at three levels by using Taguchi's orthogonal array table. The responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) are measured and the most significant parameter was confirmed by ANOVA (Analysis Of Variance). The test result shows that copper electrode material possesses higher MRR, less TWR as compared to brass and aluminium. Brass and copper tools has good surface finish as compared with aluminium. The finest electrode material for machining of Ti6Al4V alpha beta alloy in EDM process was in the order of copper, brass and aluminium.

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The analysis of material removal rate of WEDM miniature gears

Engineering review ◽

10.30765/er.1520 ◽

2021 ◽

Vol 41 (3) ◽

Author(s):

Ashish Goyal ◽

Vyom Singh ◽

Abhishek Patel

Keyword(s):

Material Removal Rate ◽

Feed Rate ◽

Material Removal ◽

Removal Rate ◽

Spur Gear ◽

Wire Edm ◽

Pulse On Time ◽

Pulse Off Time ◽

Off Time ◽

Edm Process

Gear fabrication in wire electrical discharge machining (WEDM) plays an important role in manufacturing industries. This paper describes the analysis and optimization of process parameters for the fabrication of spur gear on brass spur gear on brass workpiece (10cmx15cmx6mm) material by wire EDM process. The experiments were performed by using the design of experiment (DoE) approach and the material removal rate (MRR) was analyzed by response surface methodology technique. The effect of input parameters i.e. pulse on time, pulse off time and feed rate on MRR has been investigated. The surface geometry of the gears has been analysed by the Scanning Electron Microscopy (SEM). This study found that 0.4 μs for pulse on time, 60 μs for pulse-off time and 6 mm/min for feed rate provides improved material removal rate. The analysis of variance shows that pulse on time and feed rate are the significant parameters for the wire EDM process. The SEM image exhibits the capability of WEDM to machined miniature gear with a uniform distribution of regular-shaped craters and defect-free flank surface.

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A Study On Machining Characteristics of Al7075-NiCr-Gr Metal Matrix Composites Through Wire – Cut Electro Discharge Machining

10.21203/rs.3.rs-912680/v1 ◽

2021 ◽

Author(s):

R. Palani ◽

M. Sakthivel ◽

V. Chithambaram ◽

Geetha Palani

Keyword(s):

Removal Rate ◽

Energy Dispersive Spectrometer ◽

Stir Casting ◽

Vital Role ◽

Matrix Composites ◽

Practical Applications ◽

Electro Discharge Machining ◽

Pulse On Time ◽

Pulse Off Time ◽

Off Time

Abstract The aluminium and its alloys play a vital role in industry for their wide practical applications. In the present work, Al7075 was reinforced with Ni-Cr and graphite by Stir casting method. Further the optimization of the machined composite was done by Taguchi method. It was inferred that the MRR value of 0.056435 g/min was obtained with input parameters of 8 amps current, 52 Volt, 4 µs pulse on time, 17 µs pulse off time by machining with WEDM and SR value of 3.3 µm showing smooth surface. The material removal rate of the composite was found and the morphology of the material was analysed by SEM with associated elemental analysis by energy dispersive spectrometer (EDS). The reinforcements present in the composite were also verified. The outcome of this micro structural investigation revealed that a non-uniform distribution of graphite particles takes place at all weight percentages of graphite reinforcement.

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